Elastomeric Blend For Air Barriers Comprising Grafted Resin Components

ABSTRACT

A composition suitable for an air barrier such as an automotive tire innertube, innerliner, and aircraft tire innertube or innerliner, curing bladders, and other pneumatic devices is disclosed. The composition comprises an elastomer, a processing oil, and a grafted resin component.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Continuation of Ser. No. 10/689,942, filed Oct.21, 2003 (now allowed) and claims the priority benefit of ProvisionalApplication No. 60/424,413, filed Nov. 7, 2002, the disclosure of whichis incorporated by reference.

BACKGROUND

The present invention relates to blends of an elastomer, a processingoil, and a grafted resin component for use in air barriers.

Halobutyl rubbers, which are isobutylene-based copolymers of C₄ to C₇isoolefins and a multiolefins, are the polymers of choice for bestair-retention in tires for passenger, truck, bus and aircraft vehicles.Bromobutyl rubber, chlorobutyl rubber, and halogenated star-branchedbutyl rubbers can be formulated for these specific applications. Theselection of ingredients and additives for the final commercialformulation depends upon the balance of properties desired--namely,processing properties of the green (uncured) compound in the tire plantversus the in-service performance of the cured tire composite, as wellas the nature of the tire.

It is generally known that resins may be incorporated into air barriercompositions, see for example WO 02/48257, the prior compositions havegenerally used resins with higher glass transition temperatures, 50° C.or higher. Other background references include U.S. Pat. Nos. 4,413,067,4,513,130, 5,246,778, 6,372,851, and EP 0 651 009 A. It is believed thatthe presently disclosed air barrier compositions containing non-aromaticprocessing oils in conjunction with a grafted resin component resin canbe used in certain formulations to surprisingly improve air barrierqualities by decreasing the air permeability and brittlenesstemperature, while maintaining other desirable properties of thecompositions.

U.S. Pat. No. 4,754,793 discloses a rubber composition comprising onehundred parts by weight of at least one butyl-type rubbery polymer; fromabout 3 to about 20 parts by weight of an aromatic hydrocarbon resin(α-methylstyrene homopolymer) having a softening point of about 93° C.to about 150° C. and a Tg of about 15° C. to about 75° C.; from about 30to about 90 parts by weight of at least one carbon black, from 0 toabout 7 parts by weight of hydrocarbon extender oil, and a curingsystem.

U.S. Pat. No. 4,113,799 discloses a carbon reinforced, partiallycross-linked butyl rubber matrix sealant composition as described isparticularly suitable for use as a self-healing tire puncture sealant.The sealant composition comprises a high average molecular weight butylrubber and a low average molecular weight butyl rubber in a ratio ofhigh to low molecular weight butyl rubber of between about 20/80 to60/40, in admixture with a tackifier present in an amount between about55 and 70 weight % of the composition. A partially hydrogenated blockcopolymer may be included in the admixture.

EP 0 314 416 A2 discloses a new rubber composition comprising from about70 to about 90 parts by weight of a high molecular weight butyl-typerubbery polymer; from about 10 to about 30 parts by weight of a lowmolecular weight butyl-type rubber polymer, wherein the total amount ofpolymers described above is one hundred parts by weight, from about 30to about 90 parts by weight of at least one carbon black, and a curingsystem.

SUMMARY

A composition suitable for an air barrier is described herein andcomprises: (a) an elastomer comprising C₄ to C₇ isoolefin derived units;(b) a processing oil; (c) a material selected from (i) a graftedhydrocarbon resin, (ii) grafted oligomers having units selected from thegroup of cyclopentadiene, substituted cyclopentadiene, C₅ monomers,and/or C₉ monomers, or (iii) combinations of (i) and (ii). Thecomposition preferably has a green tack above 0.5 N/mm. Curedcompositions preferably have a brittleness temperature below −36° C. andan air permeability less than 4.0×10⁻⁸ cm³·cm/cm²·sec·atm. Suitablearticles made from the composition may include tire curing bladders,innerliners, tire innertubes, and air sleeves comprising a compositionaccording to any of the preceding claims.

A process for manufacturing an air barrier is also described herein. Theprocess comprises mixing (a) an elastomer comprising C₄ to C₇ isoolefinderived units; (b) a processing oil; (c) a grafted material obtainableby the reaction of an unsaturated acid or anhydride and (i) ahydrocarbon resin, (ii) oligomers having units selected from the groupof cyclopentadiene, substituted cyclopentadiene, C₄-C₆ conjugateddiolefins, and/or C₈-C₁₀ aromatic olefins, and (iii) combinations of (i)and (ii).

GENERAL DEFINITIONS

The term “phr” is parts per hundred rubber, and is a measure common inthe art wherein components of a composition are measured relative to amajor elastomer component, based upon 100 parts by weight of theelastomer or elastomers or based upon 100 parts by weight of theelastomer plus the secondary rubber, if included.

As used herein, in reference to Periodic Table “Groups”, the newnumbering scheme for the Periodic Table Groups are used as in HAWLEY'SCONDENSED CHEMICAL DICTIONARY 852 (13th ed. 1997).

The term “elastomer” as used herein refers to any polymer or compositionof polymers consistent with the ASTM D1566 definition. The term“elastomer” may be used interchangeably with the term “rubber”, as usedherein.

As used herein, the term “alkyl” refers to a paraffinic hydrocarbongroup which may be derived from an alkane by dropping one or morehydrogens from the formula, such as, for example, a methyl group (CH₃),or an ethyl group (CH₃CH₂), etc.

As used herein, the term “alkenyl” refers to an unsaturated paraffinichydrocarbon group which may be derived from an alkane by dropping one ormore hydrogens from the formula, such as, for example, an ethenyl group,CH₂═CH, and a propenyl group, or CH₃CH═CH, etc.

As used herein, the term “aryl” refers to a hydrocarbon group that formsa ring structure characteristic of aromatic compounds such as, forexample, benzene, naphthalene, phenanthrene, anthracene, etc., andtypically possess alternate double bonding (“unsaturation”) within itsstructure. An aryl group is thus a group derived from an aromaticcompound by dropping one or more hydrogens from the formula such as, forexample, phenyl, or C₆H₅.

By “substituted”, it is meant substitution of at least one hydrogengroup by at least one substituent selected from, for example, halogen(chlorine, bromine, fluorine, or iodine), amino, nitro, sulfoxy(sulfonate or alkyl sulfonate), thiol, alkylthiol, and hydroxy; alkyl,straight or branched chain having 1 to 20 carbon atoms which includesmethyl, ethyl, propyl, tert-butyl, isopropyl, isobutyl, etc.; alkoxy,straight or branched chain alkoxy having 1 to 20 carbon atoms, andincludes, for example, methoxy, ethoxy, propoxy, isopropoxy, butoxy,isobutoxy, secondary butoxy, tertiary butoxy, pentyloxy, isopentyloxy,hexyloxy, heptryloxy, octyloxy, nonyloxy, and decyloxy; haloalkyl, whichmeans straight or branched chain alkyl having 1 to 20 carbon atoms whichis substituted by at least one halogen, and includes, for example,chloromethyl, bromomethyl, fluoromethyl, iodomethyl, 2-chloroethyl,2-bromoethyl, 2-fluoroethyl, 3-chloropropyl, 3-bromopropyl,3-fluoropropyl, 4-chlorobutyl, 4-fluorobutyl, dichloromethyl,dibromomethyl, difluoromethyl, diiodomethyl, 2,2-dichloroethyl,2,2-dibromomethyl, 2,2-difluoroethyl, 3,3-dichloropropyl,3,3-difluoropropyl, 4,4-dichlorobutyl, 4,4-difluorobutyl,trichloromethyl, 4,4-difluorobutyl, trichloromethyl, trifluoromethyl,2,2,2-trifluoroethyl, 2,3,3-trifluoropropyl, 1,1,2,2-tetrafluoroethyl,and 2,2,3,3-tetrafluoropropyl. Thus, for example, a “substitutedstyrenic unit” includes p-methylstyrene, p-ethylstyrene, etc.

As used herein, molecular weights (number average molecular weight (Mn),weight average molecular weight (Mw), and z-average molecular weight(Mz)) are measured by Size Exclusion Chromatography using a Waters 150Gel Permeation Chromatograph equipped with a differential refractiveindex detector and calibrated using polystyrene standards. Samples arerun in tetrahydrofuran (THF) at a temperature of 45° C. Molecularweights are reported as polystyrene-equivalent molecular weights and aregenerally measured in g/mol.

As used herein aromatic content and olefin content are measured by¹H-NMR as measured directly from the ¹H NMR spectrum from a spectrometerwith a field strength greater than 300 MHz, most preferably 400 MHz(frequency equivalent). Aromatic content is the integration of aromaticprotons versus the total number of protons. Olefin proton or olefinicproton content is the integration of olefinic protons versus the totalnumber of protons.

DETAILED DESCRIPTION

The compositions disclosed herein generally comprise at least oneelastomer, preferably comprising a C₄ to C₇ isoolefin derived units, aprocessing oil, and a tackifier selected from (a) a hydrocarbon resinhaving a Tg below 50° C., (b) oligomers having units selected from thegroup of cyclopentadiene, substituted cyclopentadiene, C₄-C₆ conjugateddiolefins, and/or C₈-C₁₀ aromatic olefins, and (b) combinations of (a)and (b).

In some embodiments multiple elastomers and/or secondary rubbers (asdescribed below) may be included. Preferred processing oils includeparaffinic oils, aromatic oils, naphthenic oils, and polybuteneprocessing oils are particularly preferred. The processing oils aregenerally present at 2-20 phr, more preferably 5-15 phr.

The resin is preferably selected from the group consisting of: aliphatichydrocarbon resins, hydrogenated aliphatic hydrocarbon resins, aromatichydrocarbon resins, hydrogenated aromatic resins, aliphatic/aromatichydrocarbon resins, hydrogenated aliphatic/aromatic hydrocarbon resins,cycloaliphatic hydrocarbon resins, hydrogenated cycloaliphatic resins,cycloaliphatic/aromatic hydrocarbon resins, hydrogenatedcycloaliphatic/aromatic hydrocarbon resins, polyterpene resins,terpene-phenol resins, rosin esters, grafted versions of any of theabove, and mixtures of any two or more thereof. The compositionpreferably less than 3 phr of α-methylstyrene homopolymer having asoftening point of 93° C. to 150° C. and a Tg from 15° C. to 75° C., andpreferably comprises a hydrocarbon resin having an aromatics contentless than 50%. In a preferred embodiment the hydrocarbon resin has a Tgless than 48° C., more preferably between −30° C. and 35° C. The resinis preferably present at 2-10 phr, more preferably 4-8 phr.

The composition may further comprise one or more fillers and/orsecondary rubbers. After curing the composition is useful in a varietyof end use applications, including, but not limited to tire curingbladders, innerliners, tire innertubes, and air sleeves. Thecomposition, upon curing, yield air barriers having improved propertiessuch as decreased air and oxygen permeability and lower brittlenesstemperatures.

Elastomer

The compositions disclosed herein include at least one elastomer. Theelastomer preferably comprises C₄ to C₇ isoolefin derived units. Thesepolymers are generally homopolymers or random copolymers of C₄ to C₇isoolefin derived units. The C₄ to C₇ isoolefin derived units may beselected from isobutylene, isobutene, 2-methyl-1-butene,3-methyl-1-butene, 2-methyl-2-butene, 1-butene, 2-butene, methyl vinylether, indene, vinyltrimethylsilane, hexene, and 4-methyl-1-pentene.Further, the elastomer may also comprise multiolefin derived unitsselected from isoprene, butadiene, 2,3-dimethyl-1,3-butadiene, myrcene,6,6-dimethyl-fulvene, hexadiene, cyclopentadiene, and piperylene. Theelastomer may also comprise styrenic-derived units selected from styreneand substituted styrenes, non-limiting examples of which includechlorostyrene, methoxystyrene, indene and indene derivatives,α-methylstyrene, o-methylstyrene, m-methylstyrene, and p-methylstyrene,and p-tert-butylstyrene. The elastomer may also be halogenated.

The elastomer may also be a butyl-type rubber or branched butyl-typerubber, especially halogenated versions of these elastomers. Usefulelastomers are unsaturated butyl rubbers such as homopolymers andcopolymers of olefins or isoolefins and multiolefins, or homopolymers ofmultiolefins. These and other types of elastomers suitable for theinvention are well known and are described in RUBBER TECHNOLOGY 209-581(Maurice Morton ed., Chapman & Hall 1995), THE VANDERBILT RUBBERHANDBOOK 105-122 (Robert F. Ohm ed., R.T. Vanderbilt Co., Inc. 1990),and Edward Kresge and H. C. Wang in 8 KIRK-OTHMER ENCYCLOPEDIA OFCHEMICAL TECHNOLOGY 934-955 (John Wiley & Sons, Inc. 4th ed. 1993).Non-limiting examples of unsaturated elastomers useful in the method andcomposition are poly(isobutylene-co-isoprene), polyisoprene,polybutadiene, poly(styrene-co-butadiene), natural rubber, star-branchedbutyl rubber, and mixtures thereof. Useful elastomers may be made by anysuitable means known in the art, and the invention is not herein limitedby the method of producing the elastomer.

Butyl rubbers are prepared by reacting a mixture of monomers, themixture having at least (1) a C₄ to C₇ isoolefin monomer component suchas isobutylene with (2) a multiolefin, monomer component. The isoolefinis in a range from 70 to 99.5 wt % by weight of the total monomermixture in one embodiment, and 85 to 99.5 wt % in another embodiment.The multiolefin component is present in the monomer mixture from 30 to0.5 wt %, preferably 25 to 0.5 wt %, more preferably 20 to 0.5 wt %,more preferably 15 to 0.5 wt %, more preferably 10 to 0.5 wt % and morepreferably 8 to 0.5 wt %.

The isoolefin is a C₄ to C₇ compound, non-limiting examples of which arecompounds such as isobutylene, isobutene, 2-methyl-1-butene,3-methyl-1-butene, 2-methyl-2-butene, 1-butene, 2-butene, methyl vinylether, indene, vinyltrimethylsilane, hexene, and 4-methyl-1-pentene. Themultiolefin is a C₄ to C₁₄ multiolefin such as isoprene, butadiene,2,3-dimethyl-1,3-butadiene, myrcene, 6,6-dimethyl-fulvene, hexadiene,cyclopentadiene, and piperylene, and other monomers such as disclosed inEP 0 279 456 and U.S. Pat. Nos. 5,506,316 and 5,162,425. Otherpolymerizable monomers such as styrene and dichlorostyrene are alsosuitable for homopolymerization or copolymerization in butyl rubbers.One embodiment of the butyl rubber polymer may be obtained by reacting95 to 99.5 wt % of isobutylene with 0.5 to 8 wt % isoprene, morepreferably 0.5 wt % to 5.0 wt % isoprene. Butyl rubbers and methods oftheir production are described in detail in, for example, U.S. Pat. Nos.2,356,128, 3,968,076, 4,474,924, 4,068,051 and 5,532,312.

Suitable butyl rubbers are EXXON® BUTYL Grades ofpoly(isobutylene-co-isoprene), having a Mooney viscosity of 32±2 to 51±5(ML 1+8 at 125° C., ASTM D 1646). Another suitable butyl-type rubber isVISTANEX™ polyisobutylene rubber having a molecular weight viscosityaverage of 0.9±0.15×10⁶ to 2.11±0.23×10⁶.

The butyl rubber may also be a branched or “star-branched” butyl rubber.These rubbers are described in, for example, EP 0 678 529 B1, U.S. Pat.Nos. 5,182,333 and 5,071,913. In one embodiment, the star-branched butylrubber (“SBB”) is a composition of a butyl rubber, either halogenated ornot, and a polydiene or block copolymer, either halogenated or not. Theinvention is not limited by the method of forming the SBB. Thepolydienes/block copolymer, or branching agents (hereinafter“polydienes”), are typically cationically reactive and are presentduring the polymerization of the butyl or halogenated butyl rubber, orcan be blended with the butyl rubber to form the SBB. The branchingagent or polydiene can be any suitable branching agent, and theinvention is not limited to the type of polydiene used to make the SBB.

The SBB is typically a composition of the butyl or halogenated butylrubber as described above and a copolymer of a polydiene and a partiallyhydrogenated polydiene selected from the group including styrene,polybutadiene, polyisoprene, polypiperylene, natural rubber,styrene-butadiene rubber, ethylene-propylene-diene rubber (EPDM),ethylene-propylene rubber (EPR), styrene-butadiene-styrene andstyrene-isoprene-styrene block copolymers. These polydienes are present,based on the monomer wt %, greater than 0.3 wt %, more preferably from0.3 to 3 wt %, and more preferably 0.4 to 2.7 wt %.

One suitable SBB is SB Butyl 4266 (ExxonMobil Chemical Company, HoustonTex.), having a Mooney viscosity (ML 1+8 at 125° C., ASTM D 1646,modified) of 34 to 44. Further, cure characteristics of SB Butyl 4266are as follows: MH is 69±6 dN·m, ML is 11.5±4.5 dN·m (ASTM D 2084).

The elastomer may also be halogenated. Halogenated butyl rubber isproduced by the halogenation of the butyl rubber product describedabove. Halogenation can be carried out by any means, and thehalogenation process does not limit the invention. Methods ofhalogenating polymers such as butyl polymers are disclosed in U.S. Pat.Nos. 2,631,984, 3,099,644, 4,554,326, 4,681,921, 4,650,831, 4,384,072,4,513,116 and 5,681,901. In one embodiment, the butyl rubber ishalogenated in hexane diluent at from 4 to 60° C. using bromine (Br₂) orchlorine (Cl₂) as the halogenation agent. The halogenated butyl rubberhas a Mooney viscosity of 20 to 70 (ML 1+8 at 125° C.), more preferablyfrom 25 to 55. The halogen wt % is from 0.1 to 10 wt % based in on theweight of the halogenated butyl rubber, more preferably 0.5 to 5 wt %,and more preferably 1 to 2.5 wt %.

One suitable halogenated butyl rubber is Bromobutyl 2222 (ExxonMobilChemical Company), having a Mooney viscosity is from 27 to 37 (ML 1+8 at125° C., ASTM 1646, modified) and a bromine content from 1.8 to 2.2 wt %relative to the Bromobutyl 2222. Further, cure characteristics ofBromobutyl 2222 are as follows: MH is from 28 to 40 dN·m, ML is from 7to 18 dN·m (ASTM D 2084). Another suitable halogenated butyl rubber isBromobutyl 2255 (ExxonMobil Chemical Company), having a Mooney Viscosityis from 41 to 51 (ML 1+8 at 125° C., ASTM D 1646, modified) and abromine content from 1.8 to 2.2 wt %. Further, cure characteristics ofBromobutyl 2255 are as follows: MH is from 34 to 48 dN·m, ML is from 11to 21 dN·m (ASTM D 2084).

The elastomer may also be a branched or “star-branched” halogenatedbutyl rubber. The halogenated star-branched butyl rubber may be acomposition of a butyl rubber, either halogenated or not, and apolydiene or block copolymer, either halogenated or not. Thehalogenation process is described in detail in U.S. Pat. Nos. 4,074,035,5,071,913, 5,286,804, 5,182,333 and 6,228,978. The invention is notlimited by the method of forming the halogenated star branched butylrubber. The polydienes/block copolymer, or branching agents (hereinafter“polydienes”), are typically cationically reactive and are presentduring the polymerization of the butyl or halogenated butyl rubber, orcan be blended with the butyl or halogenated butyl rubber to form thehalogenated star branched butyl rubber. The branching agent or polydienecan be any suitable branching agent, and the invention is not limited tothe type of polydiene used to make the halogenated star branched butylrubber.

The halogenated star branched butyl rubber is typically a composition ofthe butyl or halogenated butyl rubber as described above and a copolymerof a polydiene and a partially hydrogenated polydiene selected from thegroup including styrene, polybutadiene, polyisoprene, polypiperylene,natural rubber, styrene-butadiene rubber, ethylene-propylene-dienerubber, styrene-butadiene-styrene and styrene-isoprene-styrene blockcopolymers. These polydienes are present (based on the monomer wt %) inamounts greater than 0.3 wt %, more preferably 0.3 to 3 wt %, and morepreferably 0.4 to 2.7 wt %.

A suitable halogenated star branched butyl rubber is Bromobutyl 6222(ExxonMobil Chemical Company), having a Mooney viscosity (ML 1+8 at 125°C., ASTM D 1646, modified) of 27 to 37 and a bromine content of 2.2 to2.6 wt % relative to the halogenated star branched butyl rubber.Further, cure characteristics of Bromobutyl 6222 are as follows: MH isfrom 24 to 38 dN·m, ML is from 6 to 16 dN·m (ASTM D 2084).

The elastomer may also comprise styrenic derived units. The elastomermay also be a random copolymer comprising C₄ to C₇ isoolefin derivedunits, such as isobutylene derived units, and styrenic units selectedfrom styrene and substituted styrenes such as, for example,chlorostyrene, methoxystyrene, indene and indene derivatives,α-methylstyrene, o-methylstyrene, m-methylstyrene, and p-methylstyrene,p-halomethylstyrene (also including ortho and meta-halomethylstyrene)and p-tert-butylstyrene. In one embodiment, thehalomethylstyrene-derived unit is a p-halomethylstyrene containing atleast 80%, more preferably at least 90% by weight of the para-isomer.The “halo” group can be any halogen, preferably chlorine or bromine. Thehalogenated elastomer may also include functionalized interpolymerswherein at least some of the alkyl substituents groups present in thestyrene monomer units contain benzylic halogen or some other functionalgroup described further below.

Preferred materials may be characterized as terpolymers containing C₄ toC₇ isoolefin derived units and the following monomer units randomlyspaced along the polymer chain:

wherein R¹ and R² are independently hydrogen, lower alkyl, preferably C₁to C₇ alkyl and primary or secondary alkyl halides and X is a functionalgroup such as halogen. Preferably R¹ and R² are each hydrogen. Up to 60mol % of the para-substituted styrene present in the elastomer structuremay be the functionalized structure above in one embodiment, and inanother embodiment from 0.1 to 5 mol %.

The functional group X may be halogen or a combination of a halogen andsome other functional group such which may be incorporated bynucleophilic substitution of benzylic halogen with other groups such ascarboxylic acids; carboxy salts; carboxy esters, amides and imides;hydroxy; alkoxide; phenoxide; thiolate; thioether; xanthate; cyanide;nitrile; amino and mixtures thereof. These functionalized isoolefincopolymers, their method of preparation, methods of functionalization,and cure are more particularly disclosed in U.S. Pat. No. 5,162,445, andin particular, the functionalized amines as described above.

One suitable elastomer is poly(isobutylene-co-p-methylstyrene), or“XP-50” (ExxonMobil Chemical Company, Houston Tex.). Another suitableelastomer is a terpolymer of isobutylene and p-methylstyrene containingfrom 0.5 to 20 mol % p-methylstyrene, wherein up to 60 mol % of themethyl substituent groups present on the benzyl ring contain a bromineor chlorine atom, preferably a bromine atom (p-bromomethylstyrene), aswell as a combination of p-bromomethylstyrene and other functionalgroups such as ester and ether. These halogenated elastomers arecommercially available as EXXPRO™ Elastomers (ExxonMobil ChemicalCompany, Houston Tex.), and abbreviated as “BIMS”. These isoolefincopolymers, their method of preparation and cure are more particularlydisclosed in U.S. Pat. No. 5,162,445. These elastomers have asubstantially homogeneous compositional distribution such that at least95% by weight of the polymer has a p-alkylstyrene content within 10% ofthe average p-alkylstyrene content of the polymer. Desirable copolymersare also characterized by a molecular weight distribution (Mw/Mn) ofbetween 2 and 20 in one embodiment, and less than 10 in anotherembodiment, and less than 5 in another embodiment, and less than 2.5 inyet another embodiment, and greater than 2 in yet another embodiment; apreferred viscosity average molecular weight in the range of 200,000 upto 2,000,000 and a preferred number average molecular weight in therange of 25,000 to 750,000 as determined by gel permeationchromatography.

The “elastomer”, as described herein, may also comprise a composition ofone or more of the same elastomer having differing molecular weights toyield a composition having a bimodal molecular weight distribution. Thisbimodal distribution can be achieved by, for example, having a lowmolecular weight component in the elastomer. This can be accomplished byphysically blending two different Mw polymers together, or by in situreactor blending. In one embodiment, the elastomer has a low molecularweight (weight average molecular weight) component of 5,000 Mw to 80,000Mw in one embodiment, and from 10,000 Mw to 60,000 Mw in anotherembodiment; the low molecular weight component comprising from 5 to 40wt % of the composition in one embodiment, and from 10 to 30 wt % of thecomposition in another embodiment.

In a preferred embodiment, the functionality is selected such that itcan react or form polar bonds with functional groups present in thematrix polymer, for example, acid, amino or hydroxyl functional groups,when the polymer components are mixed at high temperatures.

The XP-50 and BIMS polymers may be prepared by a slurry polymerizationof the monomer mixture using a Lewis acid catalyst, followed byhalogenation, preferably bromination, in solution in the presence ofhalogen and a radical initiator such as heat and/or light and/or achemical initiator and, optionally, followed by electrophilicsubstitution of bromine with a different functional moiety.

Preferred BIMS polymers are brominated polymers that generally containfrom 0. 1 to 5 mole % of bromomethylstyrene groups relative to the totalamount of monomer derived units in the polymer, more preferably 0.2 to3.0 mol %, more preferably 0.3 to 2.8 mol %, more preferably 0.4 to 2.5mol %, and more preferably 0.3 to 2.0 mol %, wherein a desirable rangemay be any combination of any upper limit with any lower limit.Expressed another way, preferred copolymers contain from 0.2 to 10 wt %of bromine, based on the weight of the polymer, more preferably 0.4 to 6wt %, more preferably 0.6 to 5.6 wt % and are substantially free (lessthan 0.10 wt %) of ring halogen or halogen in the polymer backbonechain. The elastomer may also be a copolymer of C₄ to C₇ isoolefinderived units (or isomonoolefin), p-methylstyrene derived units andp-halomethylstyrene derived units, wherein the p-halomethylstyrene unitsare present in the interpolymer from 0.4 to 3.0 mol % based on the totalnumber of p-methylstyrene, and wherein the para-methylstyrene derivedunits are present from 3 to 15 wt % based on the total weight of thepolymer, more preferably 4 to 10 wt %. In another embodiment, thep-halomethylstyrene is p-bromomethylstyrene.

In a preferred embodiment the elastomer may be a copolymer or terpolymerand comprises unit selected from isobutylene, isobutene,2-methyl-1-butene, 3-methyl-1-butene, 2-methyl-2-butene, 1-butene,2-butene, methyl vinyl ether, indene, vinyltrimethylsilane, hexene,4-methyl-1-pentene, isoprene, butadiene, 2,3-dimethyl-1,3-butadiene,myrcene, 6,6-dimethyl-fulvene, hexadiene, cyclopentadiene, piperylene,styrene, chlorostyrene, methoxystyrene, indene and indene derivatives,α-methylstyrene, o-methylstyrene, m-methylstyrene, and p-methylstyrene,and p-tert-butylstyrene. The copolymer or terpolymer may also behalogenated.

The elastomer may be present in compositions from 10 to 100 phr (100 phrmeaning a single elastomer or rubber present) in one embodiment, andfrom 20 to 80 phr in another embodiment, and from 30 to 70 phr in yetanother embodiment, and from 40 to 60 phr in yet another embodiment,wherein a desirable phr range for the elastomer is any upper phr limitcombined with any lower phr limit described herein.

Processing Oil

A processing oil may be present in air barrier compositions. Theprocessing oil may be selected from paraffinic oil, aromatic oils,naphthenic oils, and polybutene oils. In one embodiment, the polybuteneprocessing oil is a low molecular weight (less than 15,000 Mn)homopolymer or copolymer of olefin derived units having from 3 to 8carbon atoms, more preferably 4 to 6 carbon atoms. In yet anotherembodiment, the polybutene is a homopolymer or copolymer of a C₄raffinate. An embodiment of such low molecular weight polymers termed“polybutene” polymers is described in, for example, SYNTHETIC LUBRICANTSAND HIGH-PERFORMANCE FUNCTIONAL FLUIDS 357-392 (Leslie R. Rudnick &Ronald L. Shubkin, ed., Marcel Dekker 1999) (hereinafter “polybuteneprocessing oil” or “polybutene”).

The polybutene processing oil may be a copolymer of isobutylene-derivedunits, 1-butene derived units, and 2-butene derived units. Thepolybutene may also be a homopolymer, copolymer, or terpolymer of thethree units, wherein the isobutylene derived units are from 40 to 100 wt% of the copolymer, the 1-butene derived units are from 0 to 40 wt % ofthe copolymer, and the 2-butene derived units are from 0 to 40 wt % ofthe copolymer. In another embodiment, the polybutene is a copolymer orterpolymer of the three units, wherein the isobutylene derived units arefrom 40 to 99 wt % of the copolymer, the 1-butene derived units are from2 to 40 wt % of the copolymer, and the 2-butene derived units are from 0to 30 wt % of the copolymer. In yet another embodiment, the polybuteneis a terpolymer of the three units, wherein the isobutylene derivedunits are from 40 to 96 wt % of the copolymer, the 1-butene derivedunits are from 2 to 40 wt % of the copolymer, and the 2-butene derivedunits are from 2 to 20 wt % of the copolymer. In yet another embodiment,the polybutene is a homopolymer or copolymer of isobutylene and1-butene, wherein the isobutylene derived units are from 65 to 100 wt %of the homopolymer or copolymer, and the 1-butene derived units are from0 to 35 wt % of the copolymer.

Polybutene processing oils typically have a number average molecularweight (Mn) of less than 15,000, more preferably less than 14000, morepreferably less than 13000, more preferably less than 12000, morepreferably less than 11000, more preferably less than 10,000, morepreferably less than 9000, more preferably less than 8000, morepreferably less than 7000, more preferably less than 6000, morepreferably less than 5000, more preferably less than 4000, morepreferably less than 3000, and more preferably less than 2000. In oneembodiment, the polybutene oil has a number average molecular weight ofgreater than 400, more preferably greater than 500, more preferablygreater than 600, more preferably greater than 700, more preferablygreater than 800, and more preferably greater than 900. Preferredembodiments can be combinations of any lower molecular weight limit withany upper molecular weight limit herein. For example, in onenon-limiting embodiment of the polybutene, the polybutene has a numberaverage molecular weight of 400 to 10,000, and from 700 to 8000 inanother embodiment, and from 900 to 3000 in yet another embodiment.Useful viscosities of the polybutene processing oil are preferablygreater than greater than 35 cSt at 100° C., more preferably greaterthan 100 cSt at 100° C., and preferred ranges include 10 to 6000 cSt(centiStokes) at 100° C., and more preferably 35 to 5000 cSt at 100° C.

Examples of such a processing oil are the PARAPOL™ series of processingoils (ExxonMobil Chemical Company, Houston Tex.), such as PARAPOL™ 450,700, 950, 1300, 2400, and 2500. The PARAPOL™ series of polybuteneprocessing oils are typically synthetic liquid polybutenes, eachindividual formulation having a certain molecular weight, allformulations of which can be used in the composition. The molecularweights of the PARAPOL™ oils are from 420 Mn (PARAPOL™ 450) to 2700 Mn(PARAPOL™ 2500). The MWD of the PARAPOL™ oils range from 1.8 to 3,preferably 2 to 2.8. The density (g/ml) of PARAPOL™ processing oilsvaries from about 0.85 (PARAPOL™ 450) to 0.91 (PARAPOL™ 2500). Thebromine number (CG/G) for PARAPOL™ oils ranges from 40 for the 450 Mnprocessing oil, to 8 for the 2700 Mn processing oil.

Another suitable series of processing oils are the TPC™ series ofprocessing oils, which are commercially available from TexasPetrochemicals, LP in Houston, Tex. Suitable examples include TPC™ 150,175, 1105, 1160 and 1285. The TPC™ series of polybutene processing oilsare typically synthetic liquid polybutenes, each individual formulationhaving a certain molecular weight, all formulations of which can be usedin the composition.

Below, Table1 shows some of the properties of the TPC™ oils describedherein, wherein the viscosity was determined as per ASTM D445. TABLE 1Properties of individual TPC ™ Grades Viscosity @ Grade Mn 100° C., cSt150 500 13 175 750 85 1105 1000 220 1160 1600 662 1285 2900 3250

The elastomeric composition may include one or more types of polybuteneas a mixture, blended either prior to addition to the elastomer or withthe elastomer. The amount and identity (e.g., viscosity, Mn, etc.) ofthe polybutene processing oil mixture can be varied in this manner.Thus, TPC™ 150 can be used when low viscosity is desired in thecomposition, while TPC™ 1285 can be used when a higher viscosity isdesired, or compositions thereof to achieve some other viscosity ormolecular weight. In this manner, the physical properties of thecomposition can be controlled. As used herein process oil make include asingle oil or a composition of two or more oils used to obtain anyviscosity or molecular weight (or other property) desired, as specifiedin the ranges disclosed herein.

Other suitable processing oils include the SUNDEX™ series of oilsavailable from Sunoco, Inc., particularly SUNDEX™ 750T, 790, 790T, 8125,and 8600T and the CALSOL™ series of oils available from R. E. Carroll,particularly CALSOL™ 510, 5120, 5550, 804, 806, and 810. Properties ofthese oils can be found in THE BLUE BOOK: MATERIALS, COMPOUNDINGINGREDIENTS, MACHINERY AND SERVICES FOR RUBBER (published by RubberWorld magazine, a Lippincott & Peto publication, 1867 West Market St.,Akron, Ohio), which is incorporate herein by reference.

The processing oil or oils are generally present in the elastomericcomposition from 1 to 60 phr, preferably from 2 to 40 phr, morepreferably from 4 to 35 phr, more preferably from 5 to 30 phr, morepreferably from 5 to 25 phr, more preferably 5 to 15, more preferably 6to 14, more preferably 8 to 14, more preferably from 2 to 20 phr, morepreferably from 2 to 10 phr, wherein a preferred range of processing oilmay be any upper phr limit combined with any lower phr limit describedherein.

Resins

The compositions disclosed herein also preferably include a resinadditive, which is preferably a grafted resin component as describedbelow, in amounts between 1 to 60 phr, preferably from 2 to 40 phr, morepreferably from 2 to 35 phr, more preferably from 2 to 30 phr, morepreferably from 2 to 25 phr, more preferably 2 to 20, more preferably 2to 15, more preferably 2 to 10, more preferably from 2 to 8 phr, morepreferably from 3 to 7 phr, and more preferably 4 to 6 phr, wherein apreferred range of resin may be any upper phr limit combined with anylower phr limit described herein. The resin used in the composition maycomprise resin blends as described below.

Grafted Hydrocarbon Resin Components

As used herein, a grafted hydrocarbon resin, oligomer, and/or resinmaterial, or a combination thereof means it has been combined,contacted, and/or reacted with a graft monomer. Grafting is the processof combining, contacting, or reacting the hydrocarbon resin, oligomersand/or resin material with the graft monomer. Grafting hydrocarbonresins, oligomers, and/or resin material, or a combination thereof toinclude at least some polar functionality produces useful components formany applications such as tire innerliner formulations.

Grafted resin materials may include, but is not limited to: adhesives oradhesive components comprising (i) grafted hydrocarbon resins; (ii)grafted oligomers, (iii) grafted oligomers+ungrafted resin(s), (iv)grafted hydrocarbon resin+ungrafted resin(s), (v) grafted hydrocarbonresin+ungrafted oligomers, (vi) grafted hydrocarbon resin+graftedoligomers, (vii) grafted oligomers+ungrafted oligomers or (viii) graftedhydrocarbon resin+grafted oligomers+ungrafted resin(s) and othersuitable combinations of one or more thereof.

Suitable hydrocarbon resins that may be grafted include: aliphatichydrocarbon resins, at least partially hydrogenated aliphatichydrocarbon resins, aliphatic/aromatic hydrocarbon resins, at leastpartially hydrogenated aliphatic aromatic hydrocarbon resins,cycloaliphatic hydrocarbon resins, at least partially hydrogenatedcycloaliphatic resins, cycloaliphatic/aromatic hydrocarbon resins, atleast partially hydrogenated cycloaliphatic/aromatic hydrocarbon resins,at least partially hydrogenated aromatic hydrocarbon resins, polyterpeneresins, terpene-phenol resins, and mixtures of two or more thereof.Preferably, the resin is at least partially hydrogenated, morepreferably substantially hydrogenated, and more preferably comprisesaromatic monomers.

The resin and/or oligomers are preferably at least partiallyhydrogenated and more preferably substantially hydrogenated. As usedherein at least partially hydrogenated means that the material containsless than 90% olefinic protons, more preferably less than 75% olefinicprotons, more preferably less than 50% olefinic protons, more preferablyless than 40% olefinic protons, more preferably less than 25% olefinicprotons, more preferably less than 15% olefinic protons, more preferablyless than 10% olefinic protons, more preferably less than 9% olefinicprotons, more preferably less than 8% olefinic protons, more preferablyless than 7% olefinic protons, and more preferably less than 6% olefinicprotons. As used herein, substantially hydrogenated means that thematerial contains less than 5% olefinic protons, more preferably lessthan 4% olefinic protons, more preferably less than 3% olefinic protons,more preferably less than 2% olefinic protons, more preferably less than1% olefinic protons, more preferably less than 0.5% olefinic protons,more preferably less than 0.1% olefinic protons, and more preferablyless than 0.05% olefinic protons after hydrogenation (and beforereaction with the graft monomer). The degree of hydrogenation istypically conducted so as to minimize and preferably avoid hydrogenationof the aromatic bonds. In preferred embodiments wherein the resin and/oroligomers are substantially hydrogenated, it is believed that the graftmonomer is appended to the resin/oligomer backbone as opposed to forminga copolymer (of resin/oligomers and graft monomers) because of the lackof terminal olefinic bonds on the substantially hydrogenatedresin/oligomers (as indicated by the preferred low olefinic protonmeasurements).

In a preferred embodiment, the hydrocarbon resin/and or oligomers havean aromatic content of 1-60%, more preferably 1-40%, more preferably1-20%, more preferably 1-15%, more preferably 5-15%, more preferably10-20%, more preferably 15-20%, and in another embodiment, morepreferably 1-10%, and more preferably 5-10%, wherein any upper limit andany lower limit of aromatic content may be combined for a preferredrange of aromatic content. In one embodiment, the hydrocarbon resin tobe grafted has a softening point of 10-200° C., more preferably 10-160°C., more preferably 60-130° C., more preferably 90-130° C., morepreferably 80-120° C., more preferably 80-150° C., and more preferably90-110° C., wherein any upper limit and any lower limit of softeningpoint may be combined for a preferred softening point range. Softeningpoint (° C.) is preferably measured as a ring and ball softening pointaccording to ASTM E-28 (Revision 1996).

Suitable grafted resins include EMFR 100, 100A, and 101 available fromExxonMobil Chemical Company. In one embodiment, a grafted resincomprises hydrocarbon resins produced by the thermal polymerization ofdicyclopentadiene (DCPD) or substituted DCPD which are then grafted witha graft monomer. The resin may further include aliphatic or aromaticmonomers as described later. In another embodiment, the hydrocarbonresin is produced by the thermal polymerization of dicyclopentadiene(DCPD) or substituted DCPD and C₉ monomers or thermal or catalyticpolymerization of C₅ and C₉ monomers. In a preferred embodiment, thegrafted resins contain less than 10% aromatics in the final resinproduct. In another embodiment, the grafted resin comprises 95 wt % of athermally polymerized dicyclopentadiene resin comprising about 10%aromatics, available as Escorez 5600, grafted with maleic anhydride, and5 wt % of grafted oligomers derived from the production of Escorez 5600and also grafted with maleic anhydride.

Grafted Oligomers

The hydrocarbon resin also comprises oligomers (dimers, trimers,tetramers, pentamers, hexamers and optionally septamers and octamers),preferably derived from a petroleum distillate boiling in the range of30-210° C. The oligomers can be derived from any suitable process andare often derived as a byproduct of resin polymerization, whetherthermal or catalytic. The oligomers may be derived from processeswherein suitable DCPD, C₅ and/or C₉ monomer feeds (as described below)are oligomerized and then grafted. Suitable oligomer streams havemolecular weights (Mn) between 130-500, more preferably between 130-410,more preferably between 130-350, more preferably between 130-270, morepreferably between 200-350, and more preferably between 200-320. Theoligomers may be grafted as described herein.

The oligomers may comprise cyclopentadiene and substitutedcyclopentadiene monomers and may further comprise C₉ monomers. Inanother embodiment, the oligomers comprise C₅ monomers and may furthercomprise C₉ monomers. Other monomers may also be present, includingC₄-C₆ mono- and di-olefins and terpenes. The oligomers may also besolely C₉ monomers. Specific examples of suitable individualcyclopentadiene and substituted cyclopentadiene monomers (includingDCPD), C₉ monomers and C₅ monomers are described below. Suitableoligomers may also comprise a mixture of more or more preferred oligomermaterials as described herein.

Graft Monomers

Preferred graft monomers include any unsaturated organic compoundcontaining at least one olefinic bond and at least one polar group suchas a carbonyl group, which includes unsaturated acids and anhydrides andderivatives thereof. Preferably, the organic compound contains anethylenic unsaturation conjugated with a carbonyl group (—C═O) andpreferably contains at least one α, β olefin bond. Examples includecarboxylic acids, acid halides or anhydrides, phenols, alcohols(mono-alcohols, diols, and polyols), ethers, ketones, alkyl and aromaticamines (including polyamines), nitriles, imines, isocyanates, nitrogencompounds, halides and combinations and derivatives thereof.Representative acids and acid derivatives include carboxylic acids,anhydrides, acid halides, esters, amides, imides and their salts, bothmetallic and non-metallic. Examples include maleic, fumaric, acrylic,methacrylic, itaconic, aconitic, citraconic, himic, tetrahydrophthalic,crotonic, α-methyl crotonic, and cinnamic acids. Maleic anhydride is aparticularly preferred graft monomer. Particular examples include,itaconic anhydride, citraconic anhydride, methyl acrylate, methylmethacrylate, ethyl acrylate, ethyl methacrylate, glycidyl acrylate,monoethyl maleate, diethyl maleate, dibutyl maleate, monomethylfumarate, dimethyl fumarate, monomethyl itaconate, diethyl itaconate,acrylamide, methacrylamide, maleic acid monoamide, maleic acid diamide,maleic acid-N-monoethylamide, maleic acid-N,N-diethylamide, maleicacid-N-monobutylamide, maleic acid-N,N-dibutylamide, fumaric acidmonoamide, fumaric acid diamide, fumaric acid-N-monobutylamide, fumaricacid-N,N-dibutylamide, maleimide, N-butylmaleimide, N-phenylmaleimide,sodium acrylate, sodium methacrylate, potassium acrylate and potassiummethacrylate. Preferred graft monomers include acids, anhydrides,alcohols, amides, and imides.

Hydrocarbon Resin Production

Hydrocarbon resins are well known and are produced, for example, byFriedel-Crafts polymerisation of various feeds, which may be puremonomer feeds or refinery streams containing mixtures of variousunsaturated materials. Generally speaking, the purer the feed the easierto polymerise. For example pure styrene, pure α-methyl styrene andmixtures thereof are easier to polymerise than a C₈/C₉ refinery stream.Similarly, pure or concentrated piperylene is easier to polymerise thanC₄-C₆ refinery streams. These pure monomers are, however, more expensiveto produce than the refinery streams which are often by-products oflarge volume refinery processes.

Aliphatic hydrocarbon resins can be prepared by cationic polymerisationof a cracked petroleum feed containing C₄, C₅, and C₆ paraffins,olefins, and conjugated diolefins referred to herein as C₅ monomers. Asused herein, C₅ monomers preferably excludes DCPD monomer removed bythermal soaking as described below. These monomer streams comprisecationically and thermally polymerisable monomers such as butadiene,isobutylene, 1,3-pentadiene (piperylene) along with 1,4-pentadiene,cyclopentene, 1-pentene, 2-pentene, 2-methyl-1-pentene,2-methyl-2-butene, 2-methyl-2-pentene, isoprene, cylcohexene,1-3-hexadiene, 1-4-hexadiene, cyclopentadiene, and dicyclopentadiene. Toobtain these C₅ monomer feeds the refinery streams are preferablypurified usually by both fractionation and treatment to removeimpurities. In some embodiments, the C₅ monomer feed stream may includeat least some cyclopentadiene (CPD) and substituted cyclopentadiene(e.g, methylcyclopentadiene) components. These components are optionallyseparated from the C₅ monomer streams by thermal soaking wherein the C₅monomer feed stream is heated to a temperature between 100° C. and 150°C. for 0.5 to 6 hours followed by separation of the DCPD monomers, toreduce the level of cyclopentadiene or dicyclopentadiene in the C₅monomer stream to preferably below 2 wt %. Low temperature heat soakingis preferred in order to limit the cyclic diene (cyclopentadiene andmethylcyclopentadiene) co-dimerisation with C₅ linear conjugated dienes(isoprene and pentadienes 1,3 cis- and trans-). The thermal soaking steppreferably dimerizes the cyclopentadiene and substitutedcyclopentadiene, making separation from the C₅ monomer stream easier.After fractionation and, if carried out, thermal soaking, the feedstockis preferably subjected to distillation to remove cyclic conjugateddiolefins which are gel precursors (cyclopentadiene andmethylcyclopentadiene being removed as dimers, trimers, etc.).

One example of a C₅ monomer stream is a steam cracked petroleum streamboiling in the range of −10° C. to 100° C. Examples of commercialsamples of C₅ monomer feedstocks include Naphtha Petroleum 3 Piperylenesfrom Lyondell Petrochemical Company, Houston, Tex., regular PiperyleneConcentrate or Super Piperylene Concentrate both from Shell NederlandChemie B. V., Hoogvilet, the Netherlands.

The resin polymerization feed may also comprise C₈-C₁₀ aromatic monomers(referred to herein as C₉ monomers) such as styrene, indene, derivativesof styrene, derivatives of indene, and combinations thereof.Particularly preferred aromatic olefins include styrene,α-methylstyrene, β-methylstyrene, indene, methylindenes and vinyltoluenes. One example of a C₉ monomer stream is a steam crackedpetroleum stream boiling in the range of −10° C. to 210° C. (135° C. to210° C. if the C₅ monomers and DCPD components are not present).Examples of commercial C₉ monomer feedstocks include LRO-90 fromLyondell Petrochemical Company, Houston, Tex., DSM C₉ Resinfeed Classicfrom DSM, Geleen, the Netherlands, RO-60 and RO-80 from Dow ChemicalCompany of Midland, Mich., and Dow Resin Oil 60-L from the Dow ChemicalCompany of Terneuzen, the Netherlands.

In addition to the reactive components, non-polymerisable components inthe feed may include saturated hydrocarbons such as pentane,cyclopentane, or 2-methyl pentane that can be co-distilled with theunsaturated components. This monomer feed can be co-polymerised withother C₄ or C₅ olefins or dimers. Preferably, however, the feeds arepurified to remove unsaturated materials that adversely affect thepolymerisation reaction or cause undesirable colours in the final resin(e.g., isoprene). This is generally accomplished by fractionation. Inone embodiment, polymerization is conducted using Friedel-Craftspolymerisation catalysts such as supported or unsupported Lewis acids(e.g., boron trifluoride (BF₃), complexes of boron trifluoride,aluminium trichloride (AlCl₃), complexes of aluminium trichloride oralkyl aluminium halides, particularly chlorides). Suitable reactionconditions for Friedel-Crafts polymerisation include temperatures of−20° C. to 100° C., pressures of 100 to 2000 k Pa. C₅ and C₉ monomersmay be polymerized by such a process.

Typically, the feed stream includes between 20-80 wt % monomers and20-80 wt % solvent. Preferably, the feed stream includes 30-70 wt %monomers and 30-70 wt % of solvent. More preferably, the feed streamincludes 50-70 wt % monomers and 30-50 wt % of solvent. The solvent mayinclude an aromatic solvent, which may be toluenes, xylenes, otheraromatic solvents, aliphatic solvents and/or mixtures of two or morethereof. The solvent is preferably recycled. The solvent may comprisethe unpolymerisable component of the feed. The solvents generallycontain less than 250 ppm water, preferably less than 100 ppm water, andmost preferably less than 50 ppm water.

The feed stream may include 30-95 wt % of C₅ monomers, as describedabove and 5-70 wt % of a co-feed including at least one member selectedfrom the group consisting of pure monomer, C₉ monomers, and terpenes.Preferably, the feed stream includes about 50-85 wt % of C₅ monomers andabout 15-50 wt % of a co-feed, including at least one member selectedfrom the group consisting of pure monomer, C₉ monomers, and terpenes.

Typically, the resulting hydrocarbon resin has a number averagemolecular weight (Mn) of 400-3000, a weight average molecular weight(Mw) of 500-6000, a z-average molecular weight (Mz) of 700-15,000 and apolydispersity (PD) as measured by Mw/Mn between 1.5 and 4. As usedherein, molecular weights (number-average molecular weight (Mn),weight-average molecular weight (Mw), and z-average molecular weight(Mz)) are measured by Size Exclusion Chromatography using a Waters 150Gel Permeation Chromatograph equipped with a differential refractiveindex detector and calibrated using polystyrene standards. Samples arerun in tetrahydrofuran (THF) (45° C.). Molecular weights are reported aspolystyrene-equivalent molecular weights and are generally measured ing/mol.

The monomer feed can be co-polymerised with C₄ or C₅ olefins or theirolefinic dimers as chain transfer agents. Up to 40 wt %, preferably upto 20 wt %, of chain transfer agents may be added to obtain resins withlower and narrower molecular weight distributions than can be preparedfrom using the monomer feed alone. Chain transfer agents stop thepropagation of a growing polymer chain by terminating the chain in away, which regenerates a polymer initiation site. Components, whichbehave as chain transfer agents in these reactions include but are notlimited to, 2-methyl-1-butene, 2-methyl-2-butene or dimers or oligomersof these species. The chain transfer agent can be added to the reactionin pure form or diluted in a solvent.

A DCPD resin and/or oligomers thereof (referred to also as CPDoligomers) may be obtained by thermal polymerisation of a feedcomprising unsaturated monomers of DCPD and/or substituted DCPD. Thefeed may also comprise aromatic monomers as previously described.Generally, a mixture of (a) DCPD stream, preferably a steam crackedpetroleum distillate boiling in the range 80-200° C., more preferably140° C. to 200° C., containing dimers and codimers of cyclopentadieneand its methyl derivatives together with (b) C₉ monomers, preferably asteam cracked distillate boiling in the range 150-200° C. comprisingα-methyl styrene, vinyl toluenes, indene and methyl indene with other C₉and C₁₀ aromatics, in the weight ratio (a:b) between 90:10 to 50:50 isheated in a batch polymerization reactor to 160-320° C. at a pressure of980 kPa to 2000 kPa (more preferably 9.8×10⁵−11.7×10⁵ Pa), for 1.2 to 4hours, more preferably 1.5 to 4 hrs. Where inclusion of the oligomers isnot desired, the resulting polymerizate may steam stripped to removeinert, unreacted, and low molecular weight oligomeric components toyield a resin having a softening point in the range 80-120° C.

The resin may also be obtained by or derived from thermal polymerisationof a feed comprising C₅ monomers and C₉ monomers as previouslydescribed. In such embodiments, a mixture of (a) C₅ monomers,preferably, a steam cracked petroleum distillate boiling in the range80-200° C. containing C₅ monomers together with (b) C₉ monomers,preferably a steam cracked distillate boiling in the range 150-200° C.comprising α-methyl styrene, vinyl toluenes, indene and methyl indenewith other C₈-C₁₀ aromatics, in the weight ratio (a:b) between 90:10 to50:50 is heated in a batch polymerization reactor to 160-320° C. at apressure of 980 kPa to 2000 kPa (more preferably 9.8×10⁵−11.7×10⁵ Pa),for 1.2 to 4 hours, more preferably 1.5 to 4 hrs. Where inclusion of theoligomers is not desired, the resulting polymerizate may be steamstripped to remove inert, unreacted, and low molecular weight oligomericcomponents to yield a resin having a softening point in the range80-120° C.

The products of the polymerization process include both resin and anoligomer by-product comprising oligomers (dimers, trimers, tetramers,pentamers, and hexamers, and optionally septamers and octamers) of thefeed monomer(s). As used hereafter, resin material refers to the resin,the oligomers, or a mixture of the two. Where the oligomer by-productresults from thermal polymerization of DCPD and substituted DCPD, theoligomers are typically a complex mixture of (preferably hydrogenated asdescribed below) Diels Alder trimers and tetramers of CPD and methyl-CPDwith low levels of acyclic C₅ diolefins such as pentadiene-1,3 andisoprene.

The resin material is then preferably hydrogenated to reduce colorationand improve colour stability. Any of the known processes forcatalytically hydrogenating resin material can be used. In particularthe processes disclosed in U.S. Pat. No. 5,171,793, U.S. Pat. No.4,629,766, U.S. Pat. No. 5,502,104 and U.S. Pat. No. 4,328,090 and WO95/12623 are suitable. Generic hydrogenation treating conditions includereactions in the temperature range of about 100-350° C. and pressures ofbetween 5 atm (506 kPa) and 300 atm (30390 kPa) hydrogen (and even up to400 atm hydrogen), for example, 10-275 atm (1013-27579 kPa). In oneembodiment the temperature is in the range including 180-330° C. and thepressure is in the range including 15195-20260 kPa hydrogen. Thehydrogen to feed volume ratio to the reactor under standard conditions(25° C., 1 atm (101 kPa) pressure) typically can range from 20:1-200:1;for water-white resins 100:1-200:1 is preferred. The hydrogenatedproduct may be stripped to remove low molecular weight by-products andany solvent. This oligomeric by-product is a low-viscosity nearlycolorless liquid boiling between 250-400° C. and is preferablysubstantially hydrogenated.

The hydrogenation of the resin material may be carried out via molten orsolution based processes by either a batch wise or, more commonly, acontinuous process. Catalysts employed for the hydrogenation ofhydrocarbon resins are typically supported monometallic and bimetalliccatalyst systems based on group 6, 8, 9, 10 or 11 elements. Catalystssuch as nickel on a support (for example, nickel on alumina, nickel oncharcoal, nickel on silica, nickel on kieselguhr, etc), palladium on asupport (for example, palladium on silica, palladium on charcoal,palladium on magnesium oxide, etc) and copper and/or zinc on a support(for example copper chromite on copper and/or manganese oxide, copperand zinc on alumina, etc) are good hydrogenation catalysts. The supportmaterial is typically comprised of such porous inorganic refractoryoxides as silica, magnesia, silica-magnesia, zirconia, silica-zirconia,titania, silica-titania, alumina, silica-alumina, alumina-silicate, etc,with supports containing γ-alumina being highly preferred. Preferably,the supports are essentially free of crystalline molecular sievematerials. Mixtures of the foregoing oxides are also contemplated,especially when prepared as homogeneously as possible. Useful supportmaterials include those disclosed in the U.S. Pat. Nos. 4,686,030,4,846,961, 4,500,424, and 4,849,093. Suitable supports include alumina,silica, carbon, MgO, TiO₂, ZrO₂, Fe₂O₃ or mixtures thereof.

Another suitable process for hydrogenating the resin material isdescribed in EP 0082726. EP 0082726 describes a process for thecatalytic or thermal hydrogenation using a nickel-tungsten catalyst on agamma-alumina support wherein the hydrogen pressure is 1.47×10⁷−1.96×10⁷Pa and the temperature is in the range of 250-330° C. Afterhydrogenation the reactor mixture may be flashed and further separatedto recover hydrogenated resin material. In one embodiment, steamdistillation may be used to separate the oligomers and is preferablyconducted without exceeding 325° C. resin temperature.

The catalyst may comprise nickel and/or cobalt with one or more ofmolybdenum and/or tungsten on one or more of alumina or silica supportswherein the amount of nickel oxide and/or cobalt oxide on the supportranges from 2-10 wt %. The amount of tungsten or molybdenum oxide on thesupport after preparation ranges from 5-25 wt %. Preferably, thecatalyst contains 4-7 wt % nickel oxide and 18-22 wt % tungsten oxide.This process and suitable catalysts are described in greater detail inU.S. Pat. No. 5,820,749. In another embodiment, the hydrogenation may becarried out using the process and catalysts described in U.S. Pat. No.4,629,766. In particular, nickel-tungsten catalysts on gamma-alumina arepreferred.

The oligomers may be stripped from the resin before hydrogenation andare preferably hydrogenated before grafting. The oligomers may also behydrogenated with the resin and then stripped from the resin, yielding ahydrogenated resin and hydrogenated oligomers. At least some of theoligomers may be stripped before hydrogenation and at least somehydrogenated oligomers may be stripped after hydrogenation. Thehydrogenated resin/oligomers product may be further processed togetheras a single mixture as described below. The oligomers may also bederived from any suitable source and hydrogenated (if necessary) beforegrafting so that the oligomers before grafting are typically at leastpartially hydrogenated and preferably substantially hydrogenated.

Grafting the Resin Material

At least a portion of the resulting resin material, preferably derivedfrom a process such as that described above, may then be combined and/orcontacted with a graft monomer, typically under suitable reactionconditions and in a suitable mixing device. The reaction is preferablyconducted in the absence of significant shear. As previously described,the resin and oligomers may be grafted separately or simultaneously, andif separately, grafted oligomers may then be optionally remixed with thegrafted resin, an ungrafted resin, or any another suitable resin,adhesive component or composition as described below.

Grafting of the graft monomer preferably occurs in the presence of afree-radical initiator selected from the group consisting of organicperoxides, organic per-esters, and azo compounds. Examples of suchcompounds include benzoyl peroxide, dichlorobenzoyl peroxide, dicumylperoxide, di-tert-butyl peroxide,2,5-dimethyl-2,5-di(peroxybenzoate)hexyne-3,1,4-bis(tert-butylperoxyisopropyl)benzene,lauroyl peroxide, tert-butyl peracetate,2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3,2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,tert-butyl perbenzoate, tert-butylperphenyl acetate, tert-butylperisobutyrate, tert-butyl per-sec-octoate, tert-butyl perpivalate,cumyl perpivalate, tert-butyl hydroperoxide, tert-butylperdiethylacetate, azoisobutyronitrile, and dimethyl azoisobutyrate. Theperoxide preferably has a half-life of about 6 minutes at 160° C. withvolatile non-aromatic decomposition products and those that minimizecolor formation. Preferred peroxides include di-tert-butyl peroxide and2,5 dimethyl-2,3-di(tert-butylperoxy)hexane. The amount of peroxidecombined is typically dependent on the weight of the graft monomer. Theweight ratio of the graft monomer:peroxide in the reaction mixture maybe between 1 and 20, more preferably between about 1 and 10, morepreferably between about 1 and about 5, and even more preferably about4.

The graft monomers may be combined with the resin material at atemperature between 50-200° C., more preferably between 70-150° C., morepreferably between 70-125° C., more preferably between 140-180° C., morepreferably between 140-180° C., more preferably between 155-165° C. orbetween 165-175° C. and a pressure of typically one atmosphere buthigher pressures can be used if necessary. In another preferredembodiment, the grafting reaction occurs at temperature greater than 90°C., more preferably between 90° C. and any temperature limit describedabove, more preferably between 90° C. and 150° C., more preferablybetween 90° C. and 145° C. In general, the lower limit of the reactiontemperature is governed by the softening point of the resin as it ispreferred to conduct the grafting reactions at temperatures above thesoftening point of the material to be grafted.

The graft monomer may be combined so that the weight ratio of graftmonomer:resin material in the reaction mixture is less than 1, morepreferably less than 0.5 more preferably less than 3:10 and morepreferably less than 3:20. In a preferred embodiment, the reactionmixture is maintained in a homogenous state. The reaction mixture ispreferably agitated or stirred vigorously. The free radical initiator iscombined with the resin material-graft monomer reaction mixture eitherin one addition or preferably in a continuous or semi continuous modeduring the reaction. Residence time in the reaction zone is preferablyless than 75 minutes, more preferably less than 60 minutes, morepreferably between 10-60 minutes, even more preferably between 30-60minutes.

Where only the oligomers are grafted, the reaction temperature ispreferably between 50-200° C., more preferably between 70-150° C., morepreferably between 70-125° C., more preferably between 140-180° C., morepreferably between 140-180° C., more preferably between 155-165° C., andmore preferably about 160° C. In another embodiment the reactiontemperature is 170-185° C. In another preferred embodiment, the graftingreaction occurs at temperature greater than 90° C., more preferablybetween 90° C. and any temperature limit described above, morepreferably between 90° C. and 150° C., more preferably between 90° C.and 145° C. Other preferred ranges may include between any upper andlower temperature described in this paragraph.

The amount of graft monomer added is typically dependent on the amountof oligomer. Preferably, the oligomer:graft monomer mole ratio isbetween 5 and 0.2, more preferably between 2 and 0.5, more preferablybetween about 1.5 and 0.67 and more preferably about 1. Thereafter, theungrafted oligomers are stripped from the product and optionallyrecycled to the reaction zone. The grafted oligomers produced generallyhave a softening point between 0-120° C., more preferably between25-120° C., more preferably between 50-120° C. and even more preferablybetween 80-110° C. and color of 4-10 Gardner. Gardner color, as usedherein, is measured using ASTM D-6166. The grafted oligomer product canthen be recombined with the resin (grafted or ungrafted) from which itwas derived or combined with other resins, polymers, and/or othermaterials and formulated into and adhesive material.

Where only the resin is grafted, the reaction temperature is preferablybetween 50-200° C., more preferably between 70-150° C., more preferablybetween 70-125° C., more preferably between 140-180° C., more preferablybetween 140-180° C., more preferably between 165-175° C., and morepreferably about 170° C. In another embodiment, the grafting reactionpreferably occurs between 170-185° C. In another preferred embodiment,the grafting reaction occurs at temperature greater than 90° C., morepreferably between 90° C. and any upper temperature limit describedabove. The amount of graft monomer added is typically dependent on theamount of resin. The graft monomer:resin weight ratio in the reactionmixture is preferably less than 1:5, more preferably less than 1:10,more preferably less than 1:20, and even more preferably about 1:40.Generally, the grafting raises the softening point of the resin lessthan 10° C., more preferably less than 5° C. and produces a graftedresin having a color between 1-6 Gardner.

In another embodiment, the oligomers are not stripped from the resinproduct, and the resin and oligomers are simultaneously grafted.Reaction conditions are similar to those previously described forgrafting the resin, but the graft monomer:resin material weight ratio isgenerally kept below 0.5, more preferably below 0.25 and more preferablybelow 3:20. Upon completion of grafting, the material may be furtherstripped if required to yield a resin of the desired softening pointand/or to remove unreacted oligomers. Separation of the graftedoligomers from the grafted resin may also be made if desired, but theproduct may be used without such further processing. In many embodimentscomprising grafted resin and grafted oligomers, the weight ratio ofgrafted oligomers:grafted resin in the resin material will be greaterthan 0.005, more preferably greater than 0.01, more preferably greaterthan 0.02, more preferably greater than 0.05, and more preferablygreater than 0.1.

Grafting of the resin material can also be conducted via a solutionroute wherein the resin material dispersed in a solvent and combined,contacted and/or reacted with the graft monomer. Additionally oralternatively, the graft monomer can be dispersed in a solvent prior toadding to the resin material. These routes allow for lower reactiontemperatures (as low as 80° C. or 100° C.) and allows the choice ofdifferent peroxides having half-lives of 6 minutes at the lower reactiontemperatures. Suitable solvents include, but are not limited to,aliphatic solvents, cycloaliphatic solvents, aromatic solvents, andaromatic-aliphatic solvents. Typical examples include benzene, toluene,xylene, chlorobenzene, n-pentane, n-hexane, n-heptane, n-octane,n-decane, iso-heptane, iso-decane, iso-octane, cyclohexane, alkylcyclohexane, and combinations of two or more thereof.

It is believed that the graft monomer is grafted to the resin materialthrough an olefinic bond of the graft monomer such as an α, β olefinicbond. It is believed that by grafting the oligomers via this route, theformation of norbornyl ester groups in the grafted resin material isminimized and preferably avoided. Thus, the resulting grafted resinmaterial is substantially free of norbornyl ester groups, i.e., itpreferably contains less than 0.5 wt % norbornyl ester groups, morepreferably less than 0.1 wt %, more preferably less than 0.05 wt %, morepreferably less than 0.01 wt %. The resulting grafted oligomers and/orgrafted resin are preferably at least one of a (i) a mono-alkyl succinicacid, anhydride or derivative thereof, or (ii) a β-alkyl substitutedpropanoic acid or derivative thereof. The reaction product of the resinmaterial and graft monomer or the product of the combination of theresin material and the graft monomer may also include some oligomers ofthe graft monomer, which may or may not be removed before formulating afinal composition.

The resulting grafted resin material preferably has a softening pointbetween 15-210° C., more preferably 15-170° C., more preferably 65-140°C., more preferably 65-130° C., more preferably 80-120° C., morepreferably 90-110° C., and more preferably between about 85-110° C. Thegrafted resin material preferably has a glass transition temperature(Tg) less than 120° C., more preferably less than 110° C., morepreferably between 25-100° C., more preferably between 60-100° C., morepreferably 60-80° C., and more preferably between 35-70° C. In oneembodiment the Tg is preferably less than 50° C. Differential ScanningCalorimetry (DSC, ASTM D 341-88) was used to measure Tg. The resultinggrafted resin material preferably has a Saponification number (mg KOH/gresin material) greater than 10, more preferably greater than 12, morepreferably greater than 15, more preferably greater than 16, morepreferably greater than 17, more preferably greater than 18, morepreferably greater than 19, more preferably greater than 20, morepreferably greater than 25. The resulting grafted resin materialpreferably has an acid number greater than 10, more preferably greaterthan 15, more preferably greater than 16, more preferably greater than17, more preferably greater than 18, more preferably greater than 19,more preferably greater than 20, and more preferably greater than 25.

In one embodiment, the grafted resin material has an resinmaterial:graft monomer molar ratio between 50 and 0.5, more preferablybetween 10 and 2, more preferably between 5 and 2, more preferablybetween 1.5 and 0.67, and more preferably about 1. In some embodiments,the weight ratio of graft monomer:resin in a grafted resin product ispreferably less than 1, in other embodiments between 0.001 and 1, inother embodiments between 0.01 and 1, in other embodiments between 0.02and 1, in other embodiments between 0.1 and 1, in other embodimentsbetween 0.33 and 1, and in other embodiments between 0.01 and 0.3, andin other embodiments between 0.1 and 0.2.

Resin Blends

Resin blends may also be used. The blends comprise the grafted resinmaterial described herein include both: (i) partially grafted resinmaterial streams wherein only a portion of the resin material in aparticular stream is grafted (resulting in a mixture of grafted anun-grafted resin material); and, (ii) blends of partially or fullygrafted resin material streams with another tackifying resin. Suitableexamples of other tackifying resins include: aliphatic hydrocarbonresins, at least partially hydrogenated aliphatic hydrocarbon resins,aliphatic/aromatic hydrocarbon resins, at least partially hydrogenatedaliphatic aromatic hydrocarbon resins, cycloaliphatic hydrocarbonresins, at least partially hydrogenated cycloaliphatic resins,cycloaliphatic/aromatic hydrocarbon resins, at least partiallyhydrogenated cycloaliphatic/aromatic hydrocarbon resins, aromatichydrocarbon resins, at least partially hydrogenated aromatic hydrocarbonresins, polyterpene resins, terpene-phenol resins, rosin esters, rosinacids, resins grafted with graft monomers, and mixtures of any two ormore thereof. Suitable resins also include other resins having polarfunctionality whether produced by processes described herein or othersuitable processes.

For example, one embodiment is a composition comprising between 0.1-99wt % grafted resin material and between 1-99.9 wt % other resin. Otherembodiments comprise between 0.1-50 wt % grafted resin material, between0.1-30 wt % grafted resin material, between 0.1-20 wt % grafted resinmaterial, between 1-25 wt % grafted resin material, between 1-15 wt %grafted resin material, between 1-10 wt % grafted resin material,between 5-10 wt % grafted resin material, and between 10-30 wt % graftedmaterial.

In a preferred embodiment, the resin material comprises grafted resinand grafted oligomers in embodiments of between 0.1 and 50 wt % graftedoligomers, more preferably between 0.1 and 30 wt % grafted oligomers,more preferably between 0.1 and 20 wt % grafted oligomer, morepreferably 0.1 and 10 wt % grafted oligomers, more preferably between 1and 30 wt % grafted oligomers, more preferably between 1 and 20 wt %grafted oligomers, and more preferably between 1 and 10 wt % graftedoligomers based on the total weight of the resin material. Preferredranges also include between any upper and lower limit described in thisparagraph.

One blend is a composition comprising at least two hydrocarbon resins,wherein at least one of the resins is a grafted resin material graftedwith a graft monomer and the other resin is an ungrafted petroleumhydrocarbon resin. “At least two hydrocarbon resins” also includesembodiments of hydrocarbon resins wherein only a portion of the overallresin molecules have been grafted with a graft monomer. While the baseresin component may be the same, there are two resins—one grafted andone un-grafted resin within the resin composition. Such an embodimentmay include at least two hydrocarbon resins wherein the base resincomponents are different, e.g. a C₅/C₉ resin and a grafted CPD/C₉ resin.Other examples include any combination of ungrafted resins and graftedresin materials described herein. For example, suitable petroleumhydrocarbon resins include: aliphatic hydrocarbon resins, at leastpartially hydrogenated aliphatic hydrocarbon resins, aliphatic/aromatichydrocarbon resins, at least partially hydrogenated aliphatic aromatichydrocarbon resins, cycloaliphatic hydrocarbon resins, at leastpartially hydrogenated cycloaliphatic resins, cycloaliphatic/aromatichydrocarbon resins, at least partially hydrogenatedcycloaliphatic/aromatic hydrocarbon resins, aromatic hydrocarbon resins,at least partially hydrogenated aromatic hydrocarbon resins, polyterpeneresins, rosin esters, and terpene-phenol resins.

Secondary Rubber Component

A secondary rubber component, or “general purpose rubber” component maybe present in compositions and end use articles. These rubbers may beblended by any suitable means with the elastomer or elastomercomposition. These rubbers include, but are not limited to, naturalrubbers, polyisoprene rubber, poly(styrene-co-butadiene) rubber (SBR),polybutadiene rubber (BR), poly(isoprene-co-butadiene) rubber (IBR),styrene-isoprene-butadiene rubber (SIBR), ethylene-propylene rubber(EPR), ethylene-propylene-diene rubber (EPDM), polysulfide, nitrilerubber, propylene oxide polymers, star-branched butyl rubber andhalogenated star-branched butyl rubber, brominated butyl rubber,chlorinated butyl rubber, star-branched polyisobutylene rubber,star-branched brominated butyl (polyisobutylene/isoprene copolymer)rubber; poly(isobutylene-co-p-methylstyrene) and halogenatedpoly(isobutylene-co-p-methylstyrene), such as, for example, terpolymersof isobutylene derived units, p-methylstyrene derived units, andp-bromomethylstyrene derived units,poly(isobutylene-co-isoprene-co-p-methylstyrene), halogenatedpoly(isobutylene-co-isoprene-co-p-methylstyrene),poly(isobutylene-co-isoprene-co-styrene), halogenatedpoly(isobutylene-co-isoprene-co-styrene),poly(isobutylene-co-isoprene-co-α-methylstyrene) halogenatedpoly(isobutylene-co-isoprene-co-α-methylstyrene), and mixtures thereof.

Natural rubbers are described in detail by Subramaniam in RUBBERTECHNOLOGY 179-208 (Maurice Morton, ed., Chapman & Hall 1995). Desirableembodiments of the natural rubbers are selected from Malaysian rubbersuch as SMR CV, SMR 5, SMR 10, SMR 20, and SMR 50 and mixtures thereof,wherein the natural rubbers have a Mooney viscosity at 100° C. (ML 1+4)of 30 to 120, more preferably from 40 to 65. The Mooney viscosity testreferred to herein is in accordance with ASTM D-1646. The natural rubberis preferably present in the composition from 5 to 40 phr, morepreferably 5 to 25 phr, and more preferably 10 to 20 phr, wherein apreferred range of natural rubber may be any upper phr limit combinedwith any lower phr limit described herein.

Polybutadiene (BR) rubber is another suitable secondary rubber. TheMooney viscosity of the polybutadiene rubber as measured at 100° C. (ML1+4) may range from 35 to 70, more preferably 40 to 65, more preferably45 to 60. Some commercial examples of useful synthetic rubbers areNATSYN™ (Goodyear Chemical Company), and BUDENE™ 1207 or BR 1207(Goodyear Chemical Company). A desirable rubber is highcis-polybutadiene (cis-BR). By “cis-polybutadiene” or “highcis-polybutadiene”, it is meant that 1,4-cis polybutadiene is used,wherein the amount of cis component is at least 95%. An example of highcis-polybutadiene is BUDENE™ 1207.

Rubbers of ethylene and propylene derived units such as EPR and EPDM arealso suitable as secondary rubbers. Examples of suitable comonomers inmaking EPDM are ethylidene norbornene, 1,4-hexadiene, dicyclopentadiene,as well as others. These rubbers are described in RUBBER TECHNOLOGY260-283 (1995). A suitable ethylene-propylene rubber is commerciallyavailable as VISTALON® (ExxonMobil Chemical Company, Houston Tex.).

The secondary rubber may also be a halogenated rubber as part of aterpolymer composition. The halogenated butyl rubber may be a brominatedbutyl rubber or a chlorinated butyl rubber. General properties andprocessing of halogenated butyl rubbers are described in THE VANDERBILTRUBBER HANDBOOK 105-122 (Robert F. Ohm ed., R.T. Vanderbilt Co., Inc.1990), and in RUBBER TECHNOLOGY 311-321 (1995). Butyl rubbers,halogenated butyl rubbers, and star-branched butyl rubbers are describedby Edward Kresge and H. C. Wang in 8 KIRK-OTHMER ENCYCLOPEDIA OFCHEMICAL TECHNOLOGY 934-955 (John Wiley & Sons, Inc. 4th ed. 1993).

The secondary rubber component may include, but is not limited to, atleast one or more of brominated butyl rubber, chlorinated butyl rubber,star-branched polyisobutylene rubber, star-branched brominated butyl(polyisobutylene/isoprene copolymer) rubber; halogenatedpoly(isobutylene-co-p-methylstyrene), such as, for example, terpolymersof isobutylene derived units, p-methylstyrene derived units, andp-bromomethylstyrene derived units, and the like halomethylated aromaticinterpolymers as in U.S. Pat. No. 5,162,445; U.S. Pat. No. 4,074,035;and U.S. Pat. No. 4,395,506; halogenated isoprene and halogenatedisobutylene copolymers, polychloroprene, and the like, and mixtures ofany of the above. Some embodiments of the halogenated rubber componentare also described in U.S. Pat. No. 4,703,091 and U.S. Pat. No.4,632,963.

The secondary rubber component of the elastomer composition may bepresent in a range from up to 90 phr in one embodiment, from up to 50phr in another embodiment, from up to 40 phr in another embodiment, andfrom up to 30 phr in yet another embodiment. In yet another embodiment,the secondary rubber is present from at least 2 phr, and from at least 5phr in another embodiment, and from at least 5 phr in yet anotherembodiment, and from at least 10 phr in yet another embodiment.Preferred ranges also include any combination of any upper phr limit andany lower phr limit. For example, the secondary rubber, eitherindividually or as a blend of rubbers such as, for example NR, may bepresent from 5 phr to 40 phr in one embodiment, and from 8 to 30 phr inanother embodiment, and from 10 to 25 phr in yet another embodiment, andfrom 5 to 25 phr in yet another embodiment, and from 5 to 15 phr in yetanother embodiment, wherein a desirable range of NR may be anycombination of any upper phr limit with any lower phr limit.

The elastomeric composition may have one or more filler components suchas, for example, calcium carbonate, silica, clay and other silicateswhich may or may not be exfoliated, talc, titanium dioxide, and carbonblack. In one embodiment, the filler is carbon black or modified carbonblack, and combinations thereof. The filler may also be a blend ofcarbon black and silica. A preferred filler for such articles as tiretreads and sidewalls is reinforcing grade carbon black present from 10to 100 phr, more preferably 20 to 90 phr, more preferably 30 to 80 phr,more preferably 40 to 80 phr, and more preferably 50 to 80 phr, whereina preferred range of carbon black may be any upper phr limit combinedwith any lower phr limit described herein. Useful grades of carbonblack, as described in RUBBER TECHNOLOGY, 59-85, range from N110 toN990. More desirably, embodiments of the carbon black useful in, forexample, tire treads are N229, N351, N339, N220, N234 and N110 providedin ASTM (D3037, D1510, and D3765). Embodiments of the carbon blackuseful in, for example, sidewalls in tires, are N330, N351, N550, N650,N660, and N762. Carbon blacks suitable for innerliners and other airbarriers include N550, N660, N650, N762, N990 and Regal 85.

When clay is present as a filler, it may be a swellable clay in oneembodiment, which may or may not be exfoliated or partially exfoliatedusing an exfoliating agent. Suitable swellable clay materials includenatural or synthetic phyllosilicates, particularly smectic clays such asmontmorillonite, nontronite, beidellite, volkonskoite, laponite,hectorite, saponite, sauconite, magadite, kenyaite, stevensite and thelike, as well as vermiculite, halloysite, aluminate oxides, hydrotalciteand the like. These swellable clays generally comprise particlescontaining a plurality of silicate platelets having a thickness of 8-12Å, and contain exchangeable cations such as Na⁺, Ca⁺², K⁺ or Mg⁺²present at the interlayer surfaces. They may also be surface treated (ormodified) with intercalant surfactants or materials such as alkyl,ammonium salts.

The swellable clay may be exfoliated by treatment with organic molecules(swelling or exfoliating “agents” or “additives”) capable of undergoingion exchange reactions with the cations present at the interlayersurfaces of the layered silicate. Suitable exfoliating agents includecationic surfactants such as ammonium, alkylamines or alkylammonium(primary, secondary, tertiary and quaternary), phosphonium or sulfoniumderivatives of aliphatic, aromatic or arylaliphatic amines, phosphinesand sulfides. Desirable amine compounds (or the corresponding ammoniumion) are those with the structure R²R³R⁴N, wherein R², R³, and R⁴ are C₁to C₃₀ alkyls or alkenes in one embodiment, C₁ to C₂₀ alkyls or alkenesin another embodiment, which may be the same or different. In oneembodiment, the exfoliating agent is a so called long chain tertiaryamine, wherein at least R² is a C₁₄ to C₂₀ alkyl or alkene.

The fillers may be any size and typically range, for example, from about0.0001 μm to about 100 μm. As used herein, silica is meant to refer toany type or particle size silica or another silicic acid derivative, orsilicic acid, processed by solution, pyrogenic or the like methods andhaving a surface area, including untreated, precipitated silica,crystalline silica, colloidal silica, aluminum or calcium silicates,fumed silica, and the like.

One or more crosslinking agents are preferably used in the elastomericcompositions, especially when silica is the primary filler, or ispresent in combination with another filler. More preferably, thecoupling agent may be a bifunctional organosilane crosslinking agent. An“organosilane crosslinking agent” is any silane coupled filler and/orcrosslinking activator and/or silane reinforcing agent known to thoseskilled in the art including, but not limited to, vinyl triethoxysilane,vinyl-tris-(beta-methoxyethoxy)silane,methacryloylpropyltrimethoxysilane, gamma-amino-propyl triethoxysilane(sold commercially as A1100 by Witco),gamma-mercaptopropyltrimethoxysilane (A189 by Witco) and the like, andmixtures thereof. In one embodiment,bis-(3-triethoxysilypropyl)tetrasulfide (sold commercially as Si69 byDegussa) is employed.

A processing aid may also be present in the composition. Processing aidsinclude, but are not limited to, plasticizers, tackifiers, extenders,chemical conditioners, homogenizing agents and peptizers such asmercaptans, petroleum and vulcanized vegetable oils, mineral oils,paraffinic oils, polybutene oils, naphthenic oils, aromatic oils, waxes,resins, rosins, and the like. The aid is typically present from 1 to 70phr in one embodiment, from 3 to 60 phr in another embodiment, and from5 to 50 phr in yet another embodiment. Some commercial examples ofprocessing aids are SUNDEX™ (Sunoco), an aromatic processing oil,SUNPAR™ (Sunoco), a paraffinic processing oil, PARAPOL™ (ExxonMobilChemical Company), a polybutene liquid polymer having a number averagemolecular weight of 800 to 3000, and FLEXON™ (ExxonMobil ChemicalCompany), a paraffinic petroleum oil. Commercial examples of theseinclude, for example, FLEXON oils (which contain some aromatic moieties)and CALSOL™ (Calumet Lubricants), a naphthenic processing oil.

The compositions typically contain other components and additivescustomarily used in rubber mixes, such as effective amounts of othernondiscolored and nondiscoloring processing aids, pigments,accelerators, crosslinking and curing materials, antioxidants,antiozonants. General classes of accelerators include amines, diamines,guanidines, thioureas, thiazoles, thiurams, sulfenamides, sulfenimides,thiocarbamates, xanthates, and the like. Crosslinking and curing agentsinclude sulfur, zinc oxide, and fatty acids. Peroxide cure systems mayalso be used. The components, and other curatives, are typically presentfrom 0.1 to 10 phr in the composition.

Generally, polymer blends, for example, those used to produce tires, arecrosslinked. It is known that the physical properties, performancecharacteristics, and durability of vulcanized rubber compounds aredirectly related to the number (crosslink density) and type ofcrosslinks formed during the vulcanization reaction. (See, e.g., Helt etal., The Post Vulcanization Stabilization for NR in RUBBER WORLD, 18-23(1991)). Generally, polymer blends may be crosslinked by adding curativemolecules, for example sulfur, metal oxides, organometallic compounds,radical initiators, etc., followed by heating. In particular, thefollowing metal oxides are common useful curatives: ZnO, CaO, MgO,Al₂O₃, CrO₃, FeO, Fe₂O₃, and NiO. These metal oxides can be used aloneor in conjunction with the corresponding metal fatty acid complex (e.g.,zinc stearate, calcium stearate, etc.), or with the organic and fattyacids added alone, such as stearic acid, and optionally other curativessuch as sulfur or a sulfur compound, an alkylperoxide compound, diaminesor derivatives thereof (e.g., DIAK products sold by DuPont). (See also,Formulation Design and Curing Characteristics of NBR Mixes for Seals,RUBBER WORLD 25-30 (1993)). This method of curing elastomers may beaccelerated and is often used for the vulcanization of elastomer blends.

The acceleration of the cure process may be accomplished by adding tothe composition an amount of an accelerant, often an organic compound.The mechanism for accelerated vulcanization of natural rubber involvescomplex interactions between the curative, accelerator, activators andpolymers. Ideally, all the available curative is consumed in theformation of effective crosslinks that join together two polymer chainsand enhance the overall strength of the polymer matrix. Numerousaccelerators are known in the art and include, but are not limited to,the following: stearic acid, diphenyl guanidine (DPG),tetramethylthiuram disulfide (TMTD), 4,4′-dithiodimorpholine (DTDM),tetrabutylthiuram disulfide (TBTD), benzothiazyl disulfide (MBTS),hexamethylene-1,6-bisthiosulfate disodium salt dihydrate (soldcommercially as DURALINK™ HTS by Flexsys), 2-(morpholinothio)benzothiazole (MBS or MOR), blends of 90% MOR and 10% MBTS (MOR 90),N-tertiarybutyl-2-benzothiazole sulfenamide (TBBS), and N-oxydiethylenethiocarbamyl-N-oxydiethylene sulfonamide (OTOS), zinc 2-ethyl hexanoate(ZEH), and “thioureas”.

The materials included in the air barriers and air barrier compositionsare mixed by conventional means known to those skilled in the art, in asingle step or in stages. In one embodiment, the carbon black is addedin a different stage from zinc oxide and other cure activators andaccelerators. In another embodiment, antioxidants, antiozonants andprocessing materials are added in a stage after the carbon black hasbeen processed with the elastomeric composition, and zinc oxide is addedat a final stage to maximize compound modulus. Thus, a two to three (ormore) stage processing sequence is preferred. Additional stages mayinvolve incremental additions of filler and processing oils.

The compositions may be vulcanized by subjecting them using heat orradiation according to any conventional vulcanization process.Typically, the vulcanization is conducted at a temperature ranging fromabout 100° C. to about 250° C. in one embodiment, from 150° C. to 200°C. in another embodiment, for about 1 to 150 minutes.

Suitable elastomeric compositions for such articles as air barriers, andmore particularly tire curing bladders, innerliners, tire innertubes,and air sleeves, including gaskets and ring structures, may be preparedby using conventional mixing techniques including, for example,kneading, roller milling, extruder mixing, internal mixing (such as witha Banbury™ or Brabender™ mixer) etc. The sequence of mixing andtemperatures employed are well known to the skilled rubber compounder,the objective being the dispersion of fillers, activators and curativesin the polymer matrix without excessive heat buildup. A useful mixingprocedure utilizes a Banbury™ mixer in which the copolymer rubber,carbon black, non-black fillers, and plasticizer are added and thecomposition mixed for the desired time or to a particular temperature toachieve adequate dispersion of the ingredients. Alternatively, therubber and a portion of the carbon black (e.g., one-third to two thirds)is mixed for a short time (e.g., about 1 to 3 minutes) followed by theremainder of the carbon black and oil. Mixing is continued for about 1to 10 minutes at high rotor speed during which time the mixed componentsreach a temperature of about 140° C. Following cooling, the componentsare mixed in a second step on a rubber mill or in a Banbury™ mixerduring which the curing agent and optional accelerators, are thoroughlyand uniformly dispersed at relatively low temperature, for example,about 80° C. to about 105° C., to avoid premature curing of thecomposition. Variations in mixing will be readily apparent to thoseskilled in the art. The mixing is performed to disperse all componentsof the composition thoroughly and uniformly.

An innerliner stock is then prepared by calendering the compoundedrubber composition into sheet material having a thickness of roughly 40to 80 mil gauge and cutting the sheet material into strips ofappropriate width and length for innerliner applications.

The sheet stock at this stage of the manufacturing process is a sticky,uncured mass and is therefore subject to deformation and tearing as aconsequence of handling and cutting operations associated with tireconstruction.

The innerliner is then ready for use as an element in the constructionof a pneumatic tire. The pneumatic tire is composed of a layeredlaminate comprising an outer surface which includes the tread andsidewall elements, an intermediate carcass layer which comprises anumber of plies containing tire reinforcing fibers, (e.g., rayon,polyester, nylon or metal fibers) embedded in a rubbery matrix and aninnerliner layer which is laminated to the inner surface of the carcasslayer. Tires are normally built on a tire forming drum using the layersdescribed above. After the uncured tire has been built on the drum, theuncured tire is placed in a heated mold having an inflatable tireshaping bladder to shape it and heat it to vulcanization temperatures bymethods well known in the art. Vulcanization temperatures generallyrange from about 100° C. to about 250° C., more preferably from 125° C.to 200° C., and times may range from about one minute to several hours,more preferably from about 5 to 30 minutes. Vulcanization of theassembled tire results in vulcanization of all elements of the tireassembly, for example, the innerliner, the carcass and the outertread/sidewall layers and enhances the adhesion between these elements,resulting in a cured, unitary tire from the multi-layers.

Preferred Properties

Generally, cured compositions disclosed herein preferably have abrittleness value less than −36° C., more preferably less than −37° C.,more preferably less than −38° C., more preferably less than −39° C.,more preferably less than −40° C., more preferably less than −41° C. andeven more preferably less than −42° C.

Further, the air permeability improved (decreased) upon addition of theresin. Cured compositions preferably have an air permeability less than4.0×10⁻⁸ cm³·cm/cm²·sec·atm, more preferably less than 3.5×10⁻⁸cm³·cm/cm²·sec·atm, more preferably less than 3.0×10⁻⁸cm³·cm/cm²·sec·atm, and even more preferably less than 2.5×10⁻⁸cm³·cm/cm²·sec·atm.

The uncured compositions preferably have a green tack above 0.5 N/mm,more preferably above (3 lbs./in) 0.53 N/mm, more preferably above (3.1lbs./in) 0.54 N/mm, more preferably above (3.2 lbs./in) 0.56 N/mm, morepreferably above (3.3 lbs./in) 0.58 N/mm, more preferably above (3.4lbs./in) 0.60 N/mm, more preferably above (3.5 lbs./in) 0.61 N/mm, morepreferably above (4.0 lbs./in) 0.70 N/mm, and even more preferably above(4.25 lbs./in) 0.74 N/mm. Acceptable ranges of green tack may includeany of the values listed in this paragraph as upper and/or lower limits.

The composition can be used to make any number of articles. In oneembodiment, the article is selected from tire curing bladders,innerliners, tire innertubes, and air sleeves. Other useful goods thatcan be made using compositions include hoses, seals, molded goods, cablehousing, and other articles disclosed in THE VANDERBILT RUBBER HANDBOOK637-772 (R.T. Vanderbilt Company, Inc. 1990).

EXAMPLES

The present invention, while not meant to be limiting by, may be betterunderstood by reference to the following example and Tables.

Properties and Test Methods

Cure properties were measured using an ODR 2000 at the indicatedtemperature and 3.0 degree arc. Test specimens were cured at theindicated temperature, typically from 150° C. to 170° C., for a time (inminutes) corresponding to T90+ appropriate mold lag. When possible,standard ASTM tests were used to determine the cured compound physicalproperties. Stress/strain properties (tensile strength, elongation atbreak, modulus values, energy to break) were measured at roomtemperature using an Instron 4202 or Instron 4204. Shore A hardness wasmeasured at room temperature by using a Zwick Duromatic.

Oxygen permeability was measured using a MOCON OxTran Model 2/61operating under the principle of dynamic measurement of oxygen transportthrough a thin film as published by R. A. Pasternak et al. in 8 JOURNALOF POLYMER SCIENCE: PART A-2 467 (1970). Generally, the method is asfollows: flat film or rubber samples are clamped into diffusion cellsthat are purged of residual oxygen using an oxygen free carrier gas at60° C. The carrier gas is routed to a sensor until a stable zero valueis established. Pure oxygen or air is then introduced into the outsideof the chamber of the diffusion cells. The oxygen diffusing through thefilm to the inside chamber is conveyed to a sensor, which measures theoxygen diffusion rate.

Air permeability was tested by the following method. Thin, vulcanizedtest specimens from the sample compositions were mounted in diffusioncells and conditioned in an oil bath at 65° C. and 48 psi (331 kPa). Thetime required for air to permeate through a given specimen is recordedto determine its air permeability. Test specimens were circular plateswith 12.7-cm diameter and 0.38-mm thickness. The error (2σ) in measuringair permeability is ±0.245 (×10⁸) units.

Pierced DeMattia flex measurements at 25 and 70° C. of the unagedsamples were performed according to ASTM D-813-87 under the conditionsof 300 cycles/min and 60° bend.

The “adhesion to SBR” or “adhesion T-peel” test is based on ASTM D 413.This test is used to determine the adhesive bond strength between tworubber compounds, the same or different, after curing. Cured adhesiontests were carried out at 100° C. and at a peeling speed of 2 inches (5cm)/min. Generally, the compounds used to make up the rubber(elastomeric) compositions are prepared on a three-roll mill, orcalender, to a thickness of 2.5 mm. An adhesive backing fabric is placedon the back of each compound. Typically, approximately 500 grams ofstock blended elastomeric composition yields 16 samples which is enoughfor 8 adhesion tests in duplicate, wherein the calender is set to 2.5 mmguides spaced 11 cm apart. The face of the two compounds are pressed andbonded to one another. A small Mylar tab is placed between the twolayers of rubber compositions (SBR and test composition) on one end toprevent adhesion, and to allow approximately 2.5 inches (6.35 cm) of tabarea. The samples are then cure bonded in a curing press at thespecified conditions. One inch (2.54 cm)×6 inch (15.24 cm) specimens aredie-cut from each molded vulcanized piece. The tab of each specimen isheld by a powered driven tensioning machine (Instron 4104, 4202, or1101) and pulled at a 180° angle until separation between the two rubbercompositions occurs. The force to obtain separation and observations onthe torn specimens are reported. Other test methods are summarized inTable 2. TABLE 2 Test Methods Parameter Units Test Mooney Viscosity ML1 + 8, 125° C., MU ASTM D 1646 (BIMS polymer) (modified) MooneyViscosity ML 1 + 4, 100° C., MU ASTM D 1646 (composition) Airpermeability cm³-cm/cm²-sec-atm See text Brittleness ° C. ASTM D 746Green Strength PSI ASTM D 412 (100% Modulus) Mooney Viscosity ML 1 + 4,100° C., MU ASTM D 1646 (compound) Mooney Scorch Time T_(S)5, 125° C.,minutes ASTM D 1646 Oscillating Disk Rheometer (ODR) @ 160° C., ±3° arcML deciNewton · meter ASTM D 2084 MH dNewton · m T_(S)2 minute T_(C)90minute Cure rate dN · m/minute Physical Properties press cured Tc 90 + 2min @ 160° C. Hardness Shore A ASTM D 2240 Modulus 100% MPa ASTM D 412Tensile Strength MPa Die B, C Elongation at Break % Hot Air Aging, 72hrs. @ 125° C. Hardness Change % ASTM D 573 Tensile Change % ElongationChange % Weight Change % Tear Strength N/mm ASTM D 624 Die B & Die CFatigue-to-Failure cycles ASTM D 4482 using Cam 24 (136% extension)

The error (2σ) in the later measurement is ±0.65 Mooney viscosity units.The average stress/strain value of at least three specimens is reported.The error (2σ) in tensile measurements is ±0.47 MPa units. The error inthe fatigue-to-failure values is ±20%. The error (2σ) in measuring 100%Modulus is ±0.11 MPa units; the error (2σ) in measuring elongation is±13% units.

The components of the blends used in the Examples are shown in Tables 3and 4.

Examples 1-6

Examples 1-6 use a formulation of 100 phr Bromobutyl 2222. Othercomponents and their amounts for each Example are shown in Table 5.Examples 1-4 are comparative examples using conventional tackifiers orno resin at all. Example 5 used EMFR 100. Example 6 used EMFR 100A. Theexamples were all tested for various physical properties, the results ofwhich are outlined in Tables 6-7.

These components were mixed in a Banbury mixer in the absence of zincoxide, MBTS and sulfur at a temperature of 65° C., mixed for about 5-10minutes and discharged at about 150° C. Following cooling, thecomponents were mixed in a second step on a two-roll rubber mill duringwhich the curing agent and accelerator (zinc oxide, MBTS and sulfur)were thoroughly and uniformly dispersed at a relatively low temperature,e.g., 80° C. to 105° C. The final, green compounds, if required, weresheeted one more time on the two-roll mill. To measure cured properties,these compound compositions were cured at 150° C. for 20 minutes. Themixing was performed to disperse all components of the compositionthoroughly and uniformly.

Self-tack and tack to carcass were performed as follows. Each compoundwas cold-molded to avoid premature crosslinking crosslinking (100° C., 3minutes at 8 metric tons followed by 2 minutes at 8 metric tons). Themolded sample was 4×4×0.04 inches (10.16×10. 16 cm×0. 1 cm). All tacksamples were reinforced with a cloth backing during the second moldingstep described above. Tack bonds were formed with a 4.5 lb. (2.04 kg)roller rolled twice. T-peel measurements were carried out in an Instrontesting machine at room temperature and at a crosshead speed of 2 inches(5.08 cm)/min. Three specimens were tested with average shown in theTables 5-7. For aged tack, the molded specimens were directly exposed toair for 6 days prior to testing. During this 6-day period, they werestored in a covered container to avoid dust.

The carcass formulations were produced in two mixing stages in a Banburymixer. The first stage mixed 70 parts natural rubber, 30 parts SBR 1502(styrene butadiene rubber containing 23.5% bound styrene and no oil,available from Goodyear Tire & Rubber Co., Houston, Tex.), 50 parts N660carbon black, 10 parts CALSOL 810 processing oil, 5 parts Escorez® 1102hydrocarbon resin, 1 part each of stearic acid and TMQ and 3 parts zincoxide. After mixing the above components in a BR Banbury internal mixerfor about five minutes, the compound was removed from the mixer andformed into a sheet on a two-roll mill, then cooled to room temperature.The sheeted compound was then placed back on the two-roll mill and 2parts sulfur and 1 part TBBS were added to the compound using rolls andcross cuts to form the carcass.

Examples 5 and 6 show that compared to Comparative Example 1, improved(reduced) air permeability is obtained. Improved (longer) scorch safety(MS T-3, T-5, T-10 and T-20) is obtained with improved (shorter) curetimes (T-90). Cured physical properties (Hardness, Modulus, Tensile,Elongation, Brittleness) are not affected. Improved fatigue properties(Aged Fatigue-to-Failure, Tear Die-B and Die-C) are obtained. Examples 5and 6 show that compared to Examples 2 and 3, improved (longer) scorchsafety (MS T-3, T-5, T-10 and T-20) is obtained, with other cure andcured physical properties maintained. As noted from Tables 6-7, Examples5 and 6 show brittleness temperatures lower or close to ComparativeExamples 1-4 (recipes containing conventional resins). Overall, Examples5 and 6 also have good balance in other performance, such as airimpermeability, self-tack, tack to carcass, green strength, curecharacteristics, cured adhesion, tensile properties, tear, etc., asdetailed in Tables 6-7. TABLE 3 Components and Commercial SourcesComponent Brief Description Commercial Source Bromobutyl 2222 Brominatedisobutylene-isoprene ExxonMobil Chemical Company copolymer, 2 wt % Br(Houston, TX) PARAPOL ™ 1300 Polybutene Oil ExxonMobil Chemical Company(Houston, TX) KADOX ™ 911 High Purity French Zinc Corp. of AmericaProcess Zinc Oxide (Monaca, Pa) stearic acid Cure agent e.g., C. K.Witco Corp. (Taft, LA) sulfur cure agent e.g., R. E. Carroll (Trenton,NJ) CALSOL ™ 810 Naphthenic petroleum oil Calumet Lubricants Company(Indianapolis, IN) Maglite K Magnesium oxide C. P. Hall (Chicago, IL)Struktol 40 MS Mixture of dark aromatic hydrocarbon Struktol Co. ofAmerica resins having a softening point (Stow, OH) between 50-60° C. anda specific gravity of 1.02. MBTS 2-mercaptobenzothiazole disulfide R. T.Vanderbilt (Norwalk, CT) or Elastochem (Chardon, OH)

TABLE 4 Resin Components Resin Description Source SP Phenolic resinhaving a softening Schenectady 1068 point-90° C., Tg-53° C., and Mn-850Chemicals (Schenectady, NY) Rosin Resin, including unsaturated cyclicArizona Oil MR- carboxylic acids, Tg-7° C., Mn-300 Chemical 1085 ACompany (Panama City, FL) Esco- C₅ aliphatic hydrocarbon resin havingExxonMobil rez ® a softening point of 100° C., Tg-50° C., Chemical 1102Mn-750 Company (Houston, TX) EMFR- Hydrogenated thermally polymerizedExxonMobil 100 aromatic containing di- Chemical cyclopentadienehydrocarbon resin Company grafted with maleic anhydride (Mn- (Houston,TX) 214, Mw/Mn 2.3, Saponification No. 24, 2.55 wt % maleic anhydridecontent, softening point 98° C.) EMFR- Resin Composition comprising 95ExxonMobil 100A wt % hydrogenated thermally Chemical polymerizedaromatic containing di- Company cyclopentadiene hydrocarbon resin(Houston, TX) (available as Escorez 5600) and 5 wt % oligomers (fullboiling range) derived from production of Escorez 5600, grafted withmaleic anhydride (softening point 98° C., Saponification No. 21.26,Gardner Color 4.4)

TABLE 5 Components for Examples 1-6 Component (parts by Example weight)1 2 3 4 5 6 Bromobutyl- 100 100 100 100 100 100 2222 CARBON 60.0 60.060.0 60.0 60.0 60.0 BLACK-N- 660 Calsol-810 8.0 Stearic Acid 2.0 2.0 2.02.0 2.0 2.0 Maglite-K 0.15 0.15 0.15 0.15 0.15 0.15 SP-1068 4.0 4.0Struktol 40MS 7.0 7.0 7.0 7.0 7.0 7.0 Parapol-1300 8.0 8.0 8.0 8.0 8.0MR-1085A 4.0 Escorez 1102 4.0 EMFR 100 4.0 EMFR 100A 4.0 Kadox-911 3.003.00 3.00 3.00 3.00 3.00 Altax-(MBTS) 1.50 1.50 1.50 1.50 1.50 1.50SULFUR 0.50 0.50 0.50 0.50 0.50 0.50 TOTAL Parts 186.15 186.15 186.15186.15 186.15 186.15

TABLE 6 Results for Examples 1-6 Example 1 2 3 4 5 6 MOONEY SCORCH 135°C. MINUTES TO POINT RISE T-3 14.20 13.88 12.22 22.00 18.90 20.15 T-516.48 16.37 14.38 25.25 22.02 23.15 T-10 19.22 19.47 16.65 29.15 25.5726.57 T-20 21.68 22.25 18.57 32.47 28.50 29.55 MOONEY VISCOSITY (ML)100° C. MINUTES READING (1 + 4) 54.0 56.2 54.9 56.0 55.5 57.0 ODR ARC 3°TEMP. 160° C. MINUTE MOTOR 60 MIN-MAX 24.23 24.23 15.16 21.69 20.9621.84 M-L 8.49 9.30 8.70 9.14 8.75 9.15 M-H 32.72 31.49 23.86 30.8329.71 30.99 TS-2 3.22 3.06 2.89 4.24 3.52 3.73 Tc-25 5.12 5.04 3.71 6.785.65 5.97 Tc-50 8.08 8.09 5.08 10.05 8.67 9.06 Tc-90 32.80 26.17 17.4420.17 27.09 25.04 RATE 2.52 2.11 2.85 1.79 1.97 1.99 HARDNESS, SHORE AUNAGED 56 57 61 57 55 54 AGED 72 Hrs. @ 125° C. 62 58 60 58 58 58TENSILES UNAGED TEST @ R.T. T-90 + 2 @ 160° C. 100% MODULUS, MPa 1.211.12 1.15 1.18 1.08 1.17 200% MODULUS, MPa 2.33 2.12 1.88 2.34 2.05 2.20300% MODULUS, MPa 3.61 3.37 2.89 3.75 3.28 3.47 TENSILE, MPa 9.20 9.877.96 9.89 8.97 9.50 ELONGATION, % 781 822 760 756 786 784 TENSILES AGEDTEST @ R.T. T-90 + 2 @ 160° C. 72 Hrs. @ 125° C. 100% MODULUS, MPa 2.522.06 1.97 1.91 1.79 1.80 200% MODULUS, MPa 4.68 3.97 3.55 3.82 3.50 3.51300% MODULUS, MPa 6.27 5.51 5.02 5.44 4.95 5.06 TENSILE, MPa 8.11 8.608.82 9.91 9.74 9.49 ELONGATION, % 542 592 701 692 721 695

TABLE 7 Results for Examples 1-6 Example 1 2 3 4 5 6 FATIGUE TO FAILUREkcycles 162 227 565 210 129 93 AGED 72 Hrs. @ 125° C. kcycles 13,34035,210 88,542 29,091 25,408 34,352 UNAGED-ADHESION @ R.T.- (Self-100% NRCarcass) Tear resistance N/mm 32.22 26.48 28.63 31.82 30.16 28.47 PeakLoad-N 850.54 853.87 838.30 854.53 800.23 839.50 UNAGED-ADHESION @ 100°C.- (Self-100% NR Carcass) Tear resistance N/mm 19.13 17.10 12.78 17.9215.59 17.19 XXX = Only the backing pulled Peak Load-N 662.71 614.16548.48 627.46 576.25 654.78 UNAGED-ADHESION @ R.T. (Self-70/30 SBR/NRCarcass) Tear resistance N/mm 10.00 10.25 21.26 8.09 9.74 10.56 PeakLoad-N 380.16 568.89 750.64 229.45 386.87 505.05 UNAGED-ADHESION @ 100°C. (Self-70/30 SBR/NR Carcass) Tear resistance N/mm 5.86 6.35 9.03 4.025.09 5.48 Peak Load-N 257.43 271.72 320.13 300.43 182.05 235.97 GreenStrength Modulus @ 100% PSI 39.88 44.66 43.65 41.47 40.75 44.95 Time toDecay 75% from strain 3.17 4.82 4.90 3.41 3.70 5.09 end point min.UNAGED-DIE-B TEAR Peak Load-N 99.64 121.35 114.66 103.96 116.05 120.99Tear Resistance-N/mm 56.29 59.39 55.39 59.64 56.89 57.34 AGED-72 Hrs. @125° C.- DIE-B TEAR Peak Load-N 65.69 64.41 68.26 55.48 67.39 73.39 TearResistance-N/mm 33.69 33.73 36.31 33.25 33.04 34.65 UNAGED-DIE-C TEARPeak Load-N 62.07 73.30 59.23 68.12 65.97 72.08 Tear Resistance-N/mm34.00 36.48 34.86 36.43 34.18 35.42 AGED-72 Hrs. @ 125° C.- DIE-B TEARPeak Load-N 120.01 125.59 118.56 118.86 117.27 121.85 TearResistance-N/mm 58.26 60.09 59.94 60.64 56.93 58.03 Air Permeability-(ToAir) Cm³ · cm/cm² · sec · ATM × 10⁸ Sample # 1 2.49 2.00 2.09 2.16 2.022.02 Sample # 2 2.71 2.06 2.03 2.25 1.96 1.95 Avg. of Samples #1 and #22.61 2.03 2.06 2.21 1.99 1.99 Brittleness ° C. −38.2 −38.6 −38.6 −38.2−37.4 −39.4 Self-Tack (N/mm) 1.58 1.29 1.10 1.10 1.25 1.02 AgedSelf-Tack (N/mm) 1.86 0.34 1.07 0.80 0.93 1.17 Tack to Carcass (N/mm)0.16 0.27 0.17 0.17 0.22 0.23 Aged Tack to Carcass (N/mm) 0.32 0.33 0.230.27 0.25 0.28

1. A composition comprising: (a) an elastomer comprising C₄ to C₇isoolefin derived units; (b) a processing oil; (c) a material selectedfrom: (i) a hydrocarbon resin grafted with a graft monomer; (ii)oligomers having units selected from the group of cyclopentadiene,substituted cyclopentadiene, C₅ monomers, and/or C₉ monomers, graftedwith a graft monomer, or (iii) combinations of (i) and (ii)
 2. Thecomposition according to claim 1 wherein the hydrocarbon resin isselected from the group consisting of: aliphatic hydrocarbon resins,hydrogenated aliphatic hydrocarbon resins, aromatic hydrocarbon resins,hydrogenated aromatic resins, aliphatic/aromatic hydrocarbon resins,hydrogenated aliphatic/aromatic hydrocarbon resins, cycloaliphatichydrocarbon resins, hydrogenated cycloaliphatic resins,cycloaliphatic/aromatic hydrocarbon resins, hydrogenatedcycloaliphatic/aromatic hydrocarbon resins, polyterpene resins,terpene-phenol resins, rosin esters and mixtures of two or more thereof.3. The composition according to claim 1 comprising 2-10 phr graftedmaterial.
 4. The composition according to claim 1 comprising 4-8 phrgrafted material.
 5. The composition according to claim 1 whereinhydrocarbon resin is a thermally polymerized aromatic-containingcyclopentadiene hydrocarbon resin.
 6. The composition according to claim1 wherein the hydrocarbon resin is substantially hydrogenated beforegrafting.
 7. The composition according to claim 1 wherein the oligomersare oligomers comprising cyclopentadiene, substituted cyclopentadiene,and C₉ monomers.
 8. The composition according to claim 1 wherein theoligomers are substantially hydrogenated before grafting.
 9. Thecomposition according to claim 1 wherein the grafted material has anaromatic content less than 15%.
 10. The composition according to claim 1wherein the processing oil is selected from paraffinic oils, aromaticoils, naphthenic oils, and polybutene processing oils.
 11. Thecomposition according to claim 1 comprising 2-20 phr processing oil. 12.The composition according to claim 1 comprising 5-15 phr processing oil.13. The composition according to claim 1 wherein the graft monomer ismaleic anhydride.
 14. The composition according to claim 1 furthercomprising a filler selected from carbon black, modified carbon black,silicates, exfoliated clay, partially exfoliated clay, modifiedexfoliated clay, modified partially exfoliated clay, and mixturesthereof.
 15. The composition according to claim 1 further comprising asecondary rubber selected from natural rubbers, polyisoprene rubber,styrene-butadiene rubber (SBR), polybutadiene rubber, isoprene-butadienerubber (IBR), styrene-isoprene-butadiene rubber (SIBR),ethylene-propylene rubber, ethylene-propylene-diene rubber (EPDM),polysulfide, nitrile rubber, propylene oxide polymers,poly(isobutylene-co-p-methylstyrene), halogenatedpoly(isobutylene-co-p-methylstyrene),poly(isobutylene-co-cyclopentadiene), halogenatedpoly(isobutylene-co-cyclopentadiene),poly(isobutylene-co-isoprene-co-p-methylstyrene), halogenatedpoly(isobutylene-co-isoprene-co-p-methylstyrene),poly(isobutylene-co-isoprene-co-styrene), halogenatedpoly(isobutylene-co-isoprene-co-styrene),poly(isobutylene-co-isoprene-co-α-methylstyrene)halogenatedpoly(isobutylene-co-isoprene-co-α-methylstyrene) and mixtures thereof.16. The composition according to claim 1 wherein the elastomer comprisesunits selected from isobutylene, isobutene, 2-methyl-1-butene,3-methyl-1-butene, 2-methyl-2-butene, 1-butene, 2-butene, methyl vinylether, indene, vinyltrimethylsilane, hexene, 4-methyl-1-pentene,isoprene, butadiene, 2,3-dimethyl-1,3-butadiene, myrcene,6,6-dimethyl-fulvene, hexadiene, cyclopentadiene, piperylene, styrene,chlorostyrene, methoxystyrene, indene and indene derivatives,α-methylstyrene, o-methylstyrene, m-methylstyrene, and p-methylstyrene,and p-tert-butylstyrene.
 17. The composition according to claim 1wherein the elastomer is a terpolymer.
 18. The composition according toclaim 1 wherein the elastomer is halogenated.
 19. The compositionaccording to claim 1 further comprising a curing agent selected fromsulfur, sulfur-based compounds, metal oxides, metal oxide complexes,fatty acids, peroxides, diamines, and mixtures thereof
 20. Thecomposition according to claim 1 having a green tack above 0.5 N/mm. 21.A cured composition according to claim 19 having a brittlenesstemperature below −36° C.
 22. A cured composition according to claim 19having an air permeability less than 4.0×10⁻⁸ cm³·cm/cm²·sec·atm.
 23. Anarticle selected from tire curing bladders, innerliners, tireinnertubes, and air sleeves comprising a composition according toclaim
 1. 24. An article selected from tire curing bladders, innerliners,tire innertubes, and air sleeves comprising a grafted hydrocarbon resin,grafted oligomers having units selected from the group ofcyclopentadiene, substituted cyclopentadiene, C₅ monomers, and/or C₉monomers, and/or combinations thereof.
 25. A process for manufacturingan air barrier comprising mixing (a) an elastomer comprising C₄ to C₇isoolefin derived units; (b) a processing oil; (c) a grafted materialobtainable by the reaction of an unsaturated acid or anhydride and (i) ahydrocarbon resin, (ii) oligomers having units selected from the groupof cyclopentadiene, substituted cyclopentadiene, C₄-C₆ conjugateddiolefins, and/or C₈-C₁₀ aromatic olefins, and (iii) combinations of (i)and (ii).